Portable battery pack charging system, method for recharging a battery pack, and adapter therefor

ABSTRACT

A method for recharging a battery pack includes attaching a portable charger to a user, which portable charger includes or is attached to a self-contained power supply and wherein a first charging port of the portable charger is disposed, e.g., on a belt worn by the user, hanging the battery pack on the belt while the battery pack is physically engaged and in electrical communication with a power tool, and initiating a transfer of power from the charger to the battery pack when the first charging port is at least proximal to a second charging port that is in electrical communication with at least one battery cell of the battery pack. A portable charging system capable of performing this method, as well as an adapter for use in performing this method, are also disclosed.

CROSS-REFERENCE

This application claims priority to U.S. Provisional Application No.61/511,092 filed on Jul. 24, 2011, No. 61/564,513 filed on Nov. 29,2011, No. 61/581,950 filed on Dec. 30, 2011, and No. 61/593,533 filed onFeb. 1, 2012, the contents of all of which are hereby incorporated byreference as if fully set forth herein.

TECHNICAL FIELD

The present invention generally relates to portable battery packcharging systems for charging the battery pack of a power tool system,methods for recharging the battery pack and adapters for use with theportable battery pack charging systems.

BACKGROUND ART

Electronic adapters for use with power tools are generally known in theart.

For example, U.S. Pat. No. 7,357,526 discloses a power tool andaccessory (adapter) combination. The power tool has multiple terminalsto which a battery pack or battery assembly can be connected. Theaccessory (adapter) can be electrically connected to an unused toolterminal that is otherwise engageable by a battery pack.

U.S. Pat. No. 6,502,949 discloses an adapter designed to be interposedbetween a power tool and a battery pack. The adapter includes anadditional device for use with the power tool, such as a light, a dustcollector or a hook.

U.S. Pat. No. 6,577,104 discloses an adapter that connects a power toolto a battery pack and provides a warning function in order to inform theuser when the battery pack requires recharging.

U.S. Pat. No. 7,030,590 discloses an adapter that includes a firstelectrical contact that connects with a battery pack, a secondelectrical contact that connects with a battery charger and adischarging circuit for discharging the rechargeable batteries.

U.S. Pat. No. 7,227,335 discloses an adaptor having a battery diagnosingdevice that is interposed between a charging device and a rechargeablebattery pack.

Furthermore, US 2001/0010455 A1 discloses a battery pack for a powertool having a memory for storing use profile information concerning thebattery, a reader for uploading the use profile information from thebattery or the power tool and a computer for uploading and analyzing theuser profile information uploaded from the reader.

US 2006/0142894 A1 discloses an assist apparatus that connects to amemory located in the power tool to read information stored thereinconcerning the model or specification of the power tool and a userecord. The assist apparatus then determines whether the power tool issuitable for the work description for which the power tool is used ornot by using this information. The assist device presents the power toolsuitable for the work description when the power tool is determined notto be suitable for the work description.

US 2003/0182916 A1 discloses a power tool having a microcontroller and amemory that can calculate and store a degree of wear of the power toolas a function of sensor inputs. When maintenance is performed, thememory can be read out in order to determine whether any parts haveexceeded a predetermined degree of wear.

SUMMARY

It is an object of the present teachings to provide improved portablecharging systems, as well as methods and adapters for use in recharginga battery pack of a power tool.

This object is achieved by the invention of the independent claims.Further developments of the invention are recited in the dependentclaims.

In one aspect of the present teachings, an adapter preferably includesone or more battery terminals configured or adapted to connect to one ormore charging terminals of a charger. According to this aspect of thepresent teachings, the adapters may be configured to conduct a chargingcurrent from the charger to the battery pack, e.g., while the batterypack is connected to the power tool.

In another aspect of the present teachings, the charger is preferablyportable and may include a self-contained power supply, such as one ormore rechargeable battery cells. A means for attaching the charger to auser or a means for carrying the charger may also be provided, such as aharness, strap, belt or a back pack. In this case, the charger may beworn by the user while the user is performing power tool operations.

The charger and adapter may be configured to continuously supply acharging current to the battery pack, when necessary, or the charger andadapter may be configured to supply the charging current to the batterypack when the user attaches the battery terminals of the adapter to thecharging terminals of the charger. For example, the adapter may beprovided with a belt hook that includes the battery terminals. Thecharging terminals of the charger may be provided on, in or adjacent abelt worn by the user. Thus, when the user hangs the power tool on thetool belt, charging current may be automatically supplied to the batterypack via the adapter, if necessary.

A charging control circuit for determining whether charging currentshould be supplied to the rechargeable battery cell(s) of the batterypack and, if so, the amount and voltage of the charging current, may belocated in the adapter, in the charger or even in the battery pack.

Furthermore, a method for charging the battery pack while it isconnected to the power tool is provided. The charger is preferably wornby or attached to the user and charging operations can be performedevery time (if necessary) the user hangs the power tool on his/her toolbelt. The power for the charging may be communicated from the charger tothe battery pack either via a wired connection or wirelessly.

In other words, the adapter may include at least one input terminal forreceiving or conducting a charging current from a source ofenergy/power, such as a charger or another DC power supply, such asanother rechargeable battery pack. In this embodiment, adapter enablesthe user to charge the battery pack while the battery pack is attachedto the power tool.

Preferably, the charger may be a cordless charger that includes or isattached to a self-contained power supply, such as a rechargeablebattery.

In another aspect of the present teachings, an (the) adapter for abattery-powered tool may include, in addition or in the alternative tothe any of the preceding or following circuitry or functionality, acontroller, such as at least one central processing unit (CPU), e.g.,one or more microprocessors, and at least one memory and/or storagedevice in communication therewith. The adapter also may include one ormore communication devices configured or adapted to access a memoryand/or storage device located in the power tool, in the battery pack orin both the power tool and the battery pack. More preferably, theadapter includes circuitry configured or adapted to read data stored insuch a memory and/or storage device and/or to write data to such memoryand/or storage device.

Further, the adapter may be configured or adapted to facilitate acommunication path of a power tool system containing the adapter thatis: battery pack—power tool adapter.

In such an arrangement, the adapter is not required to contain wiringfor conducting current between the battery pack and the power tool,thereby minimizing space and manufacturing requirements. In addition orin the alternative, the adapter can be adapted or configured to be morefirmly or fixedly attached to the power tool than conventional adapters,so that the adapter will not be readily dislodged from the power toolduring operation.

In a preferred embodiment of this aspect of the present teachings, eachof the battery pack, power tool and adapter preferably comprises atleast one controller, such as at least one microprocessor ormicrocontroller. In this case, the adapter controller(s) preferablycommunicates with the battery pack controller(s) via the power toolcontroller(s) and thus the adapter controller(s) indirectlycommunicate(s) with the battery pack controller(s).

In further exemplary embodiments of this aspect of the presentteachings, the adapter may be configured or adapted to read and/or writeone or more of the following types of data or information from/to thememory or memories of the power tool and/or the battery pack:

a) one or more control programs and/or data for the power tool and/orthe battery pack, and/orb) management information for the power tool and/or the battery pack,and/orc) information indicative of the status of the battery pack and/or powertool, such as the charge/discharge state of the battery pack, remainingbattery capacity, a measured or detected value relating to current,voltage, temperature, etc., the number of additional power tooloperations that can be performed using the remaining battery capacity,and/ord) one or more values relating to operational parameters of the batterypack and/or the power tool, such as charging speed, maximum currentlimit, maximum temperature threshold, maximum charged level of thebattery cell(s), etc., and/ore) maintenance information, such as usage history, service history andinformation concerning when to replace one or more worn parts, includingany of the below-described maintenance information.

In another aspect of the present teachings, the adapter may include, inaddition or in the alternative to the any of the preceding or followingcircuitry or functionality, means for wirelessly communicating with anexternal device, e.g., an external device that comprises a data inputdevice, a controller (computing means) and/or a display. As will befurther discussed below, the wireless communication protocol is notparticularly limited according to the present teachings.

In this aspect of the present teachings, the adapter may be furtherconfigured or adapted to transmit maintenance information, whichconcerns the power tool and/or the battery pack, to the external device.The adapter may also optionally be configured or adapted to store and/ordisplay such maintenance information.

The maintenance information may be one, or any combination of two ormore, of:

(i) the date of the last maintenance check/inspection,

(ii) the result of the last maintenance check/inspection,

(iii) the accumulated or total usage (operation) time of the power tooland/or the battery pack,

(iv) the available charge or charge status (remaining battery capacity)of the battery pack,

(v) the number of charging cycles experienced by the battery pack,

(vi) the condition of one or more battery cells in the battery pack,e.g., as calculated from an internal impedance measurement of thebattery cell(s),

(vii) the expected remaining service life of one or more replaceableparts in the power tool and/or the battery pack,

(viii) a maintenance schedule for the power tool and/or the adapterand/or the battery pack,

(ix) a usage history of the power tool and/or the adapter and/or thebattery pack,

(x) a name of a person responsible for administering or managing theadapter, battery pack and/or power tool,

(xi) a serial number of the battery pack and/or the power tool,

(xii) the voltage of one or more (e.g., either individually or asummation of two or more) battery cell(s),

(xiii) the discharge current of one or more (e.g., either individuallyor a summation of two or more) battery cell(s),

(xiv) the temperature of one or more (e.g., either individually or asummation of two or more) battery cell(s),

(xv) the number of times that the battery pack and/or the power tool hasbeen switched ON and/or OFF, and/or

(xvi) the amount of charging or discharging that has occurred within apredetermined time period (e.g., the amount of discharged power duringthe previous 2 hours).

Power tools according to this aspect of the present teachings can bemanufactured with a base set of electrical functions and then the usercan easily select one or more additional electronic functions to add tothe power tool by attaching the appropriate adapter (i.e. an adapterequipped with the desired functionality). In particular, the detachableadapter may communicate one or more of the above-mentioned types ofmaintenance information concerning the power tool.

Thus, in this aspect of the present teachings, power tools can beadvantageously provided with one or more additional functions that areuser-specific. In addition or the alternative, by providing a pluralityof adapters that each perform at least one different function from theother(s), a range of functions can be provided to the power tool in anexchangeable manner.

Representative, but not limiting, examples of additional functions thatmay be implemented in the adapters according to this aspect of thepresent teachings include:

wirelessly communicating information to and/or from the power tool, suchas any of the information identified above or below, includingwirelessly communicating with an external device, such as a basestation, a workstation, a computer, a personal data assistant, a smartphone, etc.,

displaying information concerning the power tool on a display, such asany of the information identified above or below,

measuring and/or displaying and/or communicating the remaining batterycapacity of the battery pack and/or the estimated number of additionalpower tool operations of the same type that can be performed with theremaining battery capacity,

measuring and/or displaying and/or communicating the value(s) of one ormore operating parameters, e.g., a maximum current limit, stored in amemory of the battery pack and/or the power tool,measuring and/or displaying and/or communicating a detected dischargecurrent and/or power tool recommendation,providing an anti-theft function or key,identifying or communicating the person responsible for administering ormanaging the adapter, battery pack and/or power tool,inputting and/or displaying and/or communicating information concerninga change of the charging speed of the battery pack,measuring and/or displaying and/or communicating value(s) indicative ofthe operational state of the battery pack and/or the power tool, and/orany other function described in U.S. Provisional Application No.61/511,092, which additional functions are incorporated herein byreference.

The above-identified and below-described functions are intended to bedescribed individually for written description purposes, such that anyone, or any arbitrary combination of two or more, may be selected,separate from the others, for further amendments of the description orclaims.

In a preferred embodiment of the above-noted aspect of the presentteachings, the power tool system comprises a plurality of hand-heldpower tools, and each adapter is preferably adapted or configured toattach to the housing of any one of the hand-held power tools andprovide a different or additional function to the hand-held power tool.

In another aspect of the present teachings, in addition or in thealternative to the any of the preceding or following circuitry orfunctionality, a power tool system preferably includes a hand-held powertool comprising a housing having a battery pack interface, anelectrically-driven device and a first connector. A battery pack isadapted or configured to be detachably attached, e.g., directly, to thebattery pack interface and to supply current to the electrically-drivendevice. An (the) adapter preferably comprises a second connectorconfigured to be physically and electrically connected with the firstconnector in a detachable manner. The adapter is further adapted orconfigured to (i) receive power from the battery pack via the hand-heldpower tool and (ii) provide at least one additional electrical functionto the hand-held power tool or to perform at least one additionalelectrical function that the hand-held power tool is not otherwisecapable of performing. The adapter may be any one of the adaptersdescribed above or below.

Such an adapter is preferably at least partially disposed, located oraccommodated within a space between the housing and the battery packwhen the housing and battery pack are attached to each other. Morepreferably at least 50% of the longest extension of the adapter isdisposed, located or accommodated within the space between the housingand the battery pack when the housing and battery pack are attached toeach other, even more preferably at least 70%, even more preferably atleast 85% and further preferably 100%.

If the adapter of the above-noted aspect is at least partially disposed,located or accommodated between the housing and the battery pack, theembedded portion of the adapter is physically protected by the housingand/or the battery pack, e.g. when the hand-held power tool is droppedor bumps against something. Thus, this aspect of the present teachingsprovides a robust and durable structure for protecting the adapter inrugged work environments.

According to any of the above- or below-described aspects or embodimentsof the present teachings, the term “power tool” is intended to encompassa wide range of electric power tools, including but not limited toelectric power tools for processing metals, electric power tools forprocessing wood, electric power tools for processing stone, and electricpower tools for gardening. Specific examples include, but are notlimited to, electric drills, electric impact and screw drivers, electricimpact wrenches, electric grinders, electric circular saws, electricreciprocating saws, electric jig saws, electric band saws, electrichammers, electric cutters, electric chain saws, electric planers,electric nailers (including electric rivet guns), electric staplers,electric shears, electric hedge trimmers, electric lawn clippers,electric lawn mowers, electric brush cutters, electric blowers (leafblowers), electric flashlights, electric concrete vibrators and electricvacuum cleaners.

The adapters according to the present teachings may be capable of beingused with two or more of such electric power tools, so that the adapterscan be used across a range of power tool products.

In another preferred embodiment of this aspect of the present teachings,the adapter according to any preceding embodiment or aspect may beprovided without the power tool and/or the battery pack.

In each of the above embodiments, the power tool and/or battery pack is(are) preferably configured so that it (they) may be utilized regardlessof whether the adapter is attached or not.

In another aspect of the present teachings, the adapter is preferablypowered by the battery pack. However, it is also possible to provide aself-contained power supply (e.g., a rechargeable battery) in theadapter for supplying power to the adapter's electronics. In this case,the adapter may optionally be configured to obtain supplemental powerand/or a battery charging current from the battery pack, if necessary.

Further objects, advantages, features, embodiments and details of theinvention will be readily understood by the skilled person upon readingthe following detailed description and claims in view of the appendeddrawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A shows a schematic diagram of a power tool system according to afirst exemplary embodiment of the present teachings, in which theadapter directly connects only to the power tool.

FIG. 1B shows the power tool system according to the first exemplaryembodiment of the present teachings in a block diagram.

FIG. 1C shows a cutaway view of the power tool system according to thefirst exemplary embodiment of the present teachings.

FIG. 2A shows a schematic diagram of a power tool system according to asecond exemplary embodiment of the present teachings, in which anadapter directly connects only to the battery pack.

FIG. 2B shows the power tool system according to the second exemplaryembodiment of the present teachings in a block diagram.

FIG. 2C shows a cutaway view of the power tool system according to thesecond exemplary embodiment of the present teachings.

FIG. 3A shows a schematic diagram of a power tool system according to athird exemplary embodiment of the present teachings, in which an adapteris connected between the battery pack and the power tool.

FIG. 3B shows the power tool system according to the third exemplaryembodiment of the present teachings in a block diagram.

FIG. 3C shows a cutaway view of the power tool system according to thethird exemplary embodiment of the present teachings.

FIG. 4A shows a schematic diagram of a power tool system according to afourth exemplary embodiment of the present teachings, in which theadapter connects to the power tool and includes a display.

FIG. 4B shows the power tool system according to the fourth exemplaryembodiment of the present teachings in a block diagram.

FIG. 4C shows a cutaway view of the power tool system according to thefourth exemplary embodiment of the present teachings.

FIG. 5A shows a schematic diagram of a power tool system according to afifth exemplary embodiment of the present teachings, in which an adapterconnects between the battery pack and a charger.

FIG. 5B shows the power tool system according to the fifth exemplaryembodiment of the present teachings in a block diagram.

FIG. 5C shows a cutaway view of the power tool system according to thefifth exemplary embodiment of the present teachings.

FIG. 6A shows a schematic diagram of a power tool system according to asixth exemplary embodiment of the present teachings, in which an adapterconnects between the power tool and a charger.

FIG. 6B shows the power tool system according to the sixth exemplaryembodiment of the present teachings in a block diagram.

FIG. 6C shows a cutaway view of the power tool system according to thesixth exemplary embodiment of the present teachings.

FIG. 7 shows the outer appearance of a power tool system according to aseventh exemplary embodiment of the present teachings, which is afurther development of the first exemplary embodiment of the presentteachings.

FIG. 8 shows a rear view of a battery pack interface and an adapterprovided for the power tool system of the seventh exemplary embodimentof the present teachings.

FIG. 9 shows a bottom view of the battery pack interface defined orprovided on the power tool housing of the seventh exemplary embodimentof the present teachings without the battery pack attached thereto.

FIG. 10 shows the adapter detached from the power tool housing of theseventh exemplary embodiment of the present teachings.

FIG. 11 shows a representative example of a wireless communicationadapter that may be utilized with the seventh exemplary embodiment ofthe present teachings.

FIG. 12 shows the battery pack interface of the seventh exemplaryembodiment of the present teachings without the adapter attachedthereto.

FIG. 13 shows a longitudinal cross-sectional view through the power toolsystem of the seventh exemplary embodiment of the present teachingscomprising the power tool housing, the adapter and the battery pack.

FIG. 14 shows a rear, partially cut-away view of the power tool systemof FIG. 13.

FIG. 15 shows a rear cross-sectional view of the power tool and adapterof FIGS. 13 and 14 without the battery pack attached thereto.

FIG. 16 shows a cutaway view of the battery pack interface with theadapter and battery pack attached thereto.

FIG. 17 shows the bottom side of the electric unit of the power toolremoved from the power tool.

FIG. 18 shows the outer appearance of a power tool system according toan eighth exemplary embodiment of the present teachings, which is afurther development of the fourth exemplary embodiment of the presentteachings.

FIG. 19 shows a top perspective view of the adapter of the eighthexemplary embodiment of the present teachings detached from the powertool.

FIG. 20 shows a bottom perspective view of the adapter of the eighthexemplary embodiment of the present teachings attached to the batterypack interface of the power tool without the battery pack attachedthereto.

FIG. 21 shows the outer appearance of a power tool system according to aninth exemplary embodiment of the present teachings.

FIG. 22 shows a top perspective view of the adapter of the ninthexemplary embodiment of the present teachings detached from the powertool.

FIG. 23 shows the outer appearance of a power tool system according to atenth exemplary embodiment of the present teachings.

FIG. 24A shows a top perspective view of the adapter of the tenthexemplary embodiment of the present teachings detached from the powertool.

FIG. 24B shows a bottom perspective view of the adapter of the tenthexemplary embodiment of the present teachings detached from the powertool.

FIG. 25 shows a bottom perspective view of the adapter of the tenthexemplary embodiment of the present teachings attached to the batterypack interface of the power tool without the battery pack attachedthereto.

FIG. 26 shows lateral perspective view of a strap attached to thecylindrical portion of an adapter according to any of the seventh totenth exemplary embodiments.

FIG. 27 shows lateral, partially cut-away view of the strap attached tothe cylindrical portion of the adapter of FIG. 26.

FIG. 28 shows a representative circuit diagram of the battery pack, thepower tool and the wireless communication adapter according to theseventh exemplary embodiment of the present teachings, which is afurther development of the circuits and functions shown in FIGS. 1A-1C.

FIG. 29 shows a representative circuit diagram of the battery pack, thepower tool and the display adapter according to the eighth exemplaryembodiment of the present teachings, which is a further development ofthe circuits and functions shown in FIGS. 4A-4C.

FIG. 30 shows a representative circuit diagram of the battery pack, thepower tool and the lighting adapter according to the ninth exemplaryembodiment of the present teachings.

FIG. 31 shows a representative portable charging system using theembodiment of FIGS. 5A-C.

FIGS. 32A-C show front, side and rear views of a power tool systemincluding the adapter of FIGS. 6A-C.

DETAILED DESCRIPTION

Before describing presently-preferred embodiments in greater detail, afurther summary of additional features, functions, aspects, advantages,etc. of the present teachings will be provided. As was indicated above,any of these features, functions, aspects, advantages, etc. may beutilized with any other features, functions, aspects, advantages, etc.of other embodiments disclosed herein in any combination.

In certain aspects of the present teachings, the adapter are configuredor adapted to perform a communication function, e.g., to enable thebattery pack and/or power tool to communicate, e.g., wirelessly, withone or more external device(s).

In such aspects, a method for wirelessly communicating informationto/from the battery pack and/or power tool is also provided. This methodenables a wide variety of functions (e.g., any of the above- or belowdescribed function) to be performed on the battery pack and/or powertool from a remote location and/or enables information concerning thebattery pack and/or power to be displayed on the external device, e.g.,a portable device, such as a smart phone, PDA, tablet computer, laptopcomputer or a dedicated display device.

The “external device” according to the present teachings is notparticularly limited, as long as it comprises a means for communicating,e.g., wirelessly, with the adapter. The external device may generallycomprise circuitry adapted or configured to analyze and/or displayinformation transmitted from the adapter to the external device and/orto transmit information from the external device to the adapter for useby the battery pack or power tool. The external device may be “dumb” inthat it basically only comprises the communication means and thedisplay, such that the external device merely displays the informationcalculated or generated by the adapter. Or, the external device may be“smart” in that comprises the communication means and at least onecontroller, e.g., one or more microprocessors and one or more memoryand/or storage devices, such that the external device is capable ofprocessing and/or analyzing data received from the adapter, as well asgenerating data and/or instructions to be transmitted to the batterypack and/or power tool via the adapter. The external device may directlycommunicate the information to the user, e.g., via a display, or mayfurther communicate the information to another external device thatserves as an (another) interface with the user.

For example, the external device may be a hand-held or portable device,such as a mobile telephone (e.g., a “smart phone”), a personal dataassistant (PDA), a tablet computer, a portable (laptop) computer, adedicated portable electronic device, etc., or it may be a deviceintended to remain in a fixed location, such as a personal (desktop)computer, a server or a mainframe.

In the alternative, the external device may be “dumb”, such as adedicated display/input device or a phone that is not itself capable ofexecuting programs for operating the adapter, battery pack or powertool. For example, the adapter could be configured to send a text (SMS)message or email message to the phone. Or, the adapter may be configuredto send information for display on the dedicated display/input deviceand to receive information/instructions that are input at the dedicateddisplay/input device.

In each case, the external device and/or adapter may further preferablycomprise wireless communication means, such as one or more of a wirelesslocal area network (WLAN) device, e.g., a WiFi network interfacecontroller or access point (i.e. operating according to the wirelesscommunication protocol specified by IEEE 802.11), a Bluetoothcommunication device, cordless telephony or cellular (mobile) networkdevices, radio (RF) communication devices or any other type of known orfuture-developed wireless communication technology.

In another aspect of the present teachings, the power tool and/or thebattery pack may include one or more of such wireless communicationmeans, in which case the adapter may be omitted, such that the externaldevice communicates directly with the battery pack and/or the powertool.

In one embodiment of this aspect of the present teachings, the adapterenables the user to access the memory of one or both of the power tooland the battery pack, in order to modify and/or update a control programand/or data stored in the memory of the power tool and/or the batterypack.

In an exemplary embodiment of the present teachings, the adapter may beadapted or configured to enable the user to change a maximum currentlimit stored in the memory of the power tool and/or in the memory of thebattery packs. Generally speaking, cordless power tools are designed tooperate safely and reliably up to a certain (rated) current threshold.If the actual current exceeds the current threshold, the electric motor,gear transmission and/or batteries could be permanently damaged, therebyshortening the service life of the power tool and/or the battery pack.

Therefore, some known power tools and/or the battery packs include acontroller or current limiting device that controls the dischargecurrent of the battery pack, i.e. the power supply to the electric motorof the power tool. The controller or current limiting device performsthe discharge current control based upon a control program and datastored in the memory of the power tool and/or the battery pack. Forexample, the control program/data may include a current limit value(I_(limit)) for the discharge current and the controller may simply shutoff the current flow to the electric motor when the discharge currentreaches the limit value.

By setting the current limit at a relatively low value, the service lifeof the power tool and the battery pack can be maximized, because theinternal components will never experience excess (damaging) currentflows. However, if the current limit is set at a relatively low value,the operation of the power tool may be frequently interrupted due to thecurrent limit being reached, especially when heavy-duty operations arebeing performed. In this case, the user's productivity may besignificantly reduced, because it may become impossible to quicklyperform certain power tool operations.

On the other hand, if the current limit is set at a relatively highvalue, power tool operations may rarely be interrupted, therebyimproving the productivity of the user. However, the higher currentlimit may shorten the service life of the power tool and/or battery packdue to the higher currents that may be experienced by the variousinternal components.

In short, a generally inverse relationship exists between the maximumcurrent limit and the convenience of operation, i.e. power tooloperations free from interruptions or tool stoppages caused by themaximum current limit being reached or exceeded. However, the maximumcurrent limit is a variable that the user may wish to control, ratherthan only being able to operate the power tool according to anon-changeable current limit set at the factory when the tool or batterypack is manufactured.

Therefore, in this exemplary embodiment, the system is adapted orconfigured to enable the user to change the current limit value and/orother parameters via the adapter. The instructions may be directly inputat the adapter or may be communicated from the external device via theadapter. For example, the user (or another person) may set a highercurrent limit value in order to prevent disruptive interruptions or toolstoppages. In the alternative, the user may elect to set a lower currentlimit value in order to extend the service life of the power tool andthe battery pack. Naturally, the present teachings also encompass thepossibility that the user may also set various current limit values inaccordance with different power tool operations that will be performed.

In one representative example, if a heavy-duty power tool operation maybe briefly performed, the user may temporarily increase the currentthreshold value to ensure that the heavy-duty power tool operation canbe quickly and efficiently performed. However, after that operation hasbeen completed, the user may want to decrease the current thresholdvalue again in order to protect the power tool system from excessivecurrents that could cause permanent damage.

In certain aspects of the present teachings, the adapter is configuredor adapted to enable the user to access the memory of the power tooland/or the battery pack, in order to read out maintenance informationstored in the memory of the power tool and/or the battery pack.

For example, many power tools includes parts that may be replaced whenworn out or broken, such as a carbon brush of the electric motor or atrigger switch having electric contacts. In order to avoid an abrupt andunexpected failure (breakdown) of the power tool and interruption of thework, which may possibly occur at an inconvenient time, it is importantto regularly check the condition of such parts, which may be burdensomeif it is necessary to disassemble the power tool in order to check thecondition.

Moreover, each replaceable part may have a different service life, whichalso may vary significantly depending upon the actual operation time ofthe power tool and/or the manner in which the power tool is normallyused and/or any significant overload conditions experienced by the powertool or the battery pack. Therefore, even if the condition of thereplaceable parts are visually inspected on a regular basis (e.g., oncea month), it may still be difficult to obtain current and reliableinformation concerning the conditions of the various replaceable partsbetween inspections.

In the light of the foregoing, another aspect of the present teachingsprovides a power tool system having a memory that can store one or moretypes of maintenance information, including but not limited to: (i) thedate of the last check/inspection, (ii) the result of the lastcheck/inspection, (iii) the accumulated or total usage (operation) timeof the power tool and/or the battery pack, (iv) the available charge orcharge status (remaining battery capacity) of the battery pack, (v) thenumber of charging cycles experienced by the battery pack, (vi) thecondition of the battery, which may be calculated from an internalimpedance measurement of the battery cell(s), (vii) the expectedremaining service life of one or more of the replaceable parts, such ascarbon brushes or even the battery cell(s) of the battery pack, (viii) amaintenance schedule for the power tool and/or the battery pack, (ix) ausage history of the power tool and/or the adapter and/or the batterypack, (x) the name(s) of an administrator or responsible person for thetool, (xi) a serial number of the battery pack and/or the power tool,(xii) the voltage of one or more (e.g., either individually or asummation of two or more) battery cell(s), (xiii) the discharge currentof one or more (e.g., either individually or a summation of two or more)battery cell(s), (xiv) the temperature of one or more (e.g., eitherindividually or a summation of two or more) battery cell(s), (xv) thenumber of times that the battery pack and/or the power tool has beenswitched ON and/or OFF, and/or (xvi) the amount of charging ordischarging that has occurred within a predetermined time period (e.g.,the amount of discharged power during the previous 2 hours). The memorymay store only one or any arbitrary combination thereof, all of whichpossible combinations are expressly disclosed herein by reference.

This memory may be located in the power tool and/or in the battery pack,and/or even in the memory of the adapter that provides the communicationfunction. The adapter may be configured or adapted to analyze and/ordisplay this information itself and/or may be configured or adapted tocommunicate maintenance information (e.g. raw data and/or processeddata) to the external device for communication to the user and ifnecessary, for further analysis and/or processing.

In a preferred embodiment, the user may access the memory of the adapterusing the external device, e.g., a smart phone, in order to check thecurrent condition of the replaceable parts. In a further preferredembodiment, an application program (“app”) for this function may be madeavailable for downloaded from the website of the tool manufacturer oranother source.

In another aspect of the present teachings, the adapter may includeanti-theft functionality. For example, one or both of the power tool andthe battery pack may include an electronic lock, i.e. a device thatprevents operation of the power tool and/or battery pack if a “key”,e.g., a password, e.g., an encrypted password, is not received by theelectronic lock. The adapter may include communication means forcommunicating the necessary key to the electronic lock in order toenable usage of the power tool and/or battery pack.

For example, the external device, which may be a computer or serverconnected to a wireless access point (e.g., a wireless router), locatedat a manufacturing facility or a construction site may wirelesslybroadcast the key in the vicinity of the worksite. When the adapterreceives the key, the adapter communicates the key to the power tooland/or battery pack, thereby enabling usage thereof. The power tooland/or battery pack may be configured to operate for a certain amount oftime, e.g., one hour, one day, etc., after receiving the key and to thenrequire the key to be re-input again within the certain period of timein order to continue uninterrupted operation of the power tool and/orbattery pack. If the key is not timely received, the electronic lock mayinternally shut off operation of the power tool and/or battery pack in amanner that can not be overridden unless the adapter, battery pack orpower tool is brought into communication with the external device again.Such an embodiment provides a theft-deterrence, because the power tooland/or battery pack can only be used at a worksite where the key isbeing broadcast.

Naturally, other possibilities for communicating the key to the powertool and/or battery pack via the adapter are possible, such as wiredconnections. In such an embodiment, the adapter may be directlyconnected to the external device in order to enable usage of the adapterand/or to communicate the key to the adapter. In this case, the adapterwould be required to be physically proximal to the external device or toat least an interface of the external device in order to obtain thenecessary key.

In another aspect of the present teachings, the adapter may includefunctionality that better enables construction companies and/ormanufacturing companies to manage a large number of power tools andbattery packs that are commonly or interchangeably used by a pluralityof users. In particular, adapters according to this aspect of thepresent teachings address the problem that some of the power tools andthe battery packs may be lost or may prematurely breakdown.

According to this aspect of the present teachings, an administrator maybe appointed for each one of the power tools and the battery packs.Further, the maintenance information of the power tool and the batterypack, respectively, may preferably include information identifying thename of the administrator thereof. In this case, when the power tool orthe battery pack breaks down, a tool manager in the company can confirmwho the administrator of the battery pack is and/or power tool by usingan external device, such as a smart phone, in order to ascertain thecause of the problem.

In another aspect of the present teachings, the adapter may be capableof providing advice or a recommendation, e.g., to the user,administrator or tool manager, as to the most appropriate power tool fora particular power tool operation.

For example, the adapter may include a circuit that monitors thedischarge current supplied to the electronic motor of the power toolduring a power tool operation. The detected discharge current is thensupplied to the controller of the adapter for analysis, or the detecteddischarge current is communicated to the external device for processingeither directly by the battery pack or power tool or via the adapterconnected to one or both of the battery pack and power tool. Thecontroller of the adapter or the external device may then determinewhether another power tool and/or battery pack having a higher or lowerrated power output is more appropriate for the power tool operationbeing performed.

As utilized herein, the term “detected discharge current” is intended toinclude, but is not limited to, an actual or transitory current measuredat any time during a single power tool operation, a peak currentmeasured during a single power tool operation, an average or meancurrent supplied during a single power tool operation, a current profilemeasured over the single power tool operation, an average of peakcurrents measured over a plurality of power tool operations or a peak,average or mean current measured over a plurality of power tooloperations.

In one exemplary embodiment, the “detected discharge current” may becompared to an upper current threshold and/or to a lower currentthreshold stored in a memory within the adapter, the power tool and/orthe battery pack. If the detected discharge current is greater than theupper current threshold, the controller may recommend the use of a powertool having a higher rated or nominal power output, in order to ensurethat the currently-used power tool is not overloaded, which may lead tooverheating and thus permanent damage to the power tool or battery pack.On the other hand, if the detected discharge current is less than thelower current threshold, the controller may recommend the use of a powertool having a lower rated or nominal power output, which may be alighter tool and thus less cumbersome and/or tiring to operate.

In another exemplary embodiment, the detected discharge current may beused as an index for a look up table (LUT) that contains a set of powertools and corresponding current ranges. By looking up the power tool(s)corresponding to the detected discharge current in the LUT, thecontroller may be capable of recommending a specific power tool, or acategory of power tool(s) based upon rated output power, for further usein performing the current power tool operation.

In another exemplary embodiment, a transitory (e.g., peak) or averagepower output may be determined based upon the detected discharge currentand may be used as an index for a look up table (LUT) that contains aset of power tools and corresponding current ranges.

Naturally, the determination as to the most appropriate power tool forthe current power tool operation may be performed in a variety of ways,including by providing an algorithm that calculates the necessary outputpower required to perform the power tool operation based upon thedetected discharge current and/or power output.

As will be discussed below, the recommendation concerning the mostappropriate power tool for a particular power tool operation may becommunicated to the user, the tool administrator, the tool manager oranother person either via a display on the adapter or via a display onthe external device. Naturally, this information may also becommunicated in an audible manner, including by providing an audio alarmin case the recommended current or power output of the power tool isbeing exceeded, e.g., by a certain percentage or by a nominal currentamount or wattage amount.

In another aspect of the present teachings, the adapter may beconfigured or adapted to enable the user, tool administrator, toolmanager or another person to change the charging speed, and/or thecharging current and/or the maximum threshold temperature for thebattery pack.

As is well known, slower charging typically uses lower current(s) and isthus less damaging to the battery cells. Therefore, slower chargingtypically extends or maximizes the service life of the battery cells.However, as a tradeoff, the charging time is longer and thus workproductivity may be negatively influenced if the user must wait for thebattery pack to complete recharging. On the other hand, the chargingspeed can be increased, e.g., by increasing the charging current and/orthe battery pack threshold temperature, which reduces total chargingtime, but possibly also reduces battery cell life.

Normally, the charging speed is set at the factory, such that the useris not permitted to individually decide which charging speed is mostappropriate for the intended usage of the battery pack. In thealternative, the charger may only be provided with two charging options,i.e. a fast charge and a slow charge. Therefore, by providing thischarging speed functionality in the adapter, the user has greaterfreedom to varying the charging speed as appropriate in order tomaximize productivity and/or maximize battery service life.

The adapter may be configured to change the charging speed by directlyinputting the instructions at the adapter, e.g., via a touch pad, touchpanel, toggle switch or push button(s), or the adapter may be configuredto receive the charging instructions from the external device. Again, an“app” may be downloaded from the tool manufacturer or another source toprovide this functionality to the adapter and/or to the external device.For example, the app may be downloaded to the external device, theexternal device may execute the app and then simply transmit aninstruction to the adapter. In the alternative, the app may bedownloaded from the external device into the adapter and then theadapter controller may execute the app.

In another aspect of the present teachings, the adapter, battery packand/or power tool may enable the user to set the maximum charged levelof the battery pack. Similar to be preceding aspect of the presentteachings, although the maximum charged level is normally set at thefactory, the user may wish to modify this value in order to optimize thebattery pack performance and/or service life for the user's intendedusage of the battery pack.

As utilized herein, the term “maximum charged level” is intended to meeta value indicative of the timing for stopping a charging operation basedupon the remaining battery capacity of the battery cell(s).

For example, if the “maximum charged level” of a battery pack having anominal capacity of 2.0 amp-hours (Ah) is 95%, it means that the 2.0 Ahnominal capacity battery will be charged up to a remaining batterycapacity of 1.9 Ah and the charging operation will be terminated, eventhough the battery could be charged further. Similarly, a “maximumcharged level” of 80% means that the 2.0 Ah nominal capacity batterywill be charged up to a remaining battery capacity of 1.6 Ah and thecharging operation will be terminated.

By terminating the charging at a lower charged level, the service lifeof the battery can be increased, e.g., including increasing ormaximizing the total number of possible charge/discharge cycles of thebattery. However, if the battery is recharged to less than its fullcapacity, the number or amount of power tool operations that can beperformed per charging cycle will be less, and possibly significantlyless if the maximum charged level is a relatively low value.

If the user normally only uses the battery pack relatively briefly, thenthe user may wish to extend the battery service life by utilizing alower maximum charged level. On the other hand, if the user normallyuses the battery pack continuously and possibly throughout the workday,then the user may wish to increase the amount of work that can be donebefore having to replace the depleted battery pack with a rechargedbattery pack, thereby improving productivity. In this case, the user maywish to set the maximum charged level relatively high.

The present teachings enable the user to change the maximum chargedlevel by either inputting a new value via an input device on theadapter, e.g., a touch screen, up/down buttons or other push buttons,such as a keyboard, or by inputting the new value at the external device(e.g., a computer, PDA or phone). In the latter case, the externaldevice may transmit the new value to the battery pack and/or power toolvia the adapter, or even directly to the battery pack and/or power tool.

In another aspect of the present teachings, the adapter may beconfigured or adapted to enable the power tool and the battery pack toaccess the external device (e.g., the user's smart phone) in order totransmit, e.g., wirelessly, information indicative of the state ofbattery charge/discharge.

Such an adapter may improve worker productivity by ensuring the user istimely supplied with a fully charged battery pack when needed. In thisregard, it is noted that the charge storage capacity of the battery packmay not be sufficient to drive the power tool all day long, or at leastuntil an extended break sufficient to recharge the battery pack.Therefore, when the battery pack is discharged and is no longer capableof supplying energy to the power tool, it is necessary replace thedischarged battery pack with a recharged battery pack in order to keepworking. In other words, a recharged battery pack must be ready when thebattery pack currently in use is no longer capable of driving the powertool or work productivity may suffer.

Thus, in this aspect of the present teachings, the adapter can beconfigured to provide useful information concerning the charge status ofthe battery pack, as well as provide reliable predictions concerning howmuch longer the currently-used battery pack is expected to continue toprovide power before becoming fully discharged. For example, the adaptermay analyze the type of work currently being performed by the user,e.g., tightening screws, in view of the remaining battery charge of thebattery pack and output a prediction concerning, e.g., how manyadditional screws can be tightened with the current battery pack beforeit must be replaced, i.e. before its energy is depleted.

As will be discussed below, the adapter of this embodiment may eitherinclude a display that directly shows the user the charge status and/orprediction concerning the remaining power tool operations that can beperformed, or the adapter may transmit this information, e.g.,wirelessly, to an external device for display.

In the alternative, the adapter may simply transmit raw data, e.g., avalue indicative of the current discharge battery voltage, orpartially-processed data, e.g., a value indicative of the energy outputof the currently-performed power tool operation. Then, the externaldevice may perform the necessary calculations to determine the remainingbattery charge and/or the predicted number of remaining power tooloperations before the battery pack requires recharging.

The adapter may also transmit information concerning the type ofoperation currently being performed and/or information indicative of thepower consumed by each currently-performed power tool operation. Forexample, the adapter may dynamically measure the “detected dischargecurrent” (as defined above) in order to provide a more precise estimateof the power consumption for each power tool operation currently beingperformed, because various factors may affect the power consumption of aparticular operation, such as screwing in a screw. That is, the hardnessof the material, into which the screw is being driven, will affect powerconsumption, as harder materials generally require more power for thesame size screw. Similarly, the size of the screw affects the powerconsumption, as larger screws generally consume more power for the samematerial. Naturally, the presence or absence of a pilot hole will alsoaffect the power consumption.

Therefore, by dynamically measuring the actual power consumption of thecurrently performed power tool operation, a fairly precise estimate canbe provided as to the number of additional power tool operations of thesame type that can still be performed with the remaining batterycapacity of the battery pack.

In addition or in the alternative, the user may input informationconcerning the current usage of the tool and the external device mayperform the necessary information using a stored value, whichcorresponds to the average power usage for the inputted power tooloperation, and the remaining battery capacity.

Again, an “app” may be downloaded from the tool manufacturer's websiteor another source in order to provide this function in the externaldevice.

In addition or in the alternative, the adapter may transmit the raw data(measured discharge voltage) or calculated remaining battery capacity,to a server or to a smart phone of the tool manager. In this case, theexternal device may notify the tool administrator or tool manager whenit is time to deliver a recharged battery pack to the user whose batterypack is approaching the fully discharged state, e.g., by performing thecalculations as to the number of remaining power tool operations thatmay be performed. For example, the external device may also store one ormore time values indicating the average or typical amount of time (whichmay be empirically determined) that a particular power tool operationtakes, and then the external device can provide an estimate as to theamount of time (e.g. in minutes) that the user can be expected tocontinue to operate the power tool before the currently-used batterypack will be depleted of energy.

In addition or in the alternative, the adapter may transmit otherdischarge-related information concerning the power tool and/or thebattery pack to the external device (e.g., smart phone) of the toolmanager. For example, the discharge-related information may include atemperature detected within the power tool and/or the battery pack.Generally speaking, a power tool that has exceeded a certain temperaturethreshold may indicate that it is currently being operated in anoverloaded state. If the user were to continue to operate the power tooland/or the battery pack in the overloaded state, the power tool and/orthe battery pack could be permanently damaged by the excessive heat.

In order to prevent damage caused by overheating (i.e. overloadedconditions), the adapter may be configured or adapted to transmit awarning signal or an alarm signal to the external device (e.g., thesmart phone) of the user or the tool manager when the power tool and/orthe battery pack is overheated. In this case, the tool manager may benotified in order to deliver another power tool and/or the battery packto the user, or the user may be directly warned by the alarm to stopusage of the overheated power tool system.

As was described above, the power tool system of this aspect of thepresent teachings may also be configured or adapted to permit changes tothe maximum temperature threshold as input either via the adapter or theexternal device by the user, a tool administrator, a tool manager, etc.

In addition or in the alternative to all the foregoing embodiments andaspects, the adapter may optionally include a display, such as a liquidcrystal display (LCD), light-emitting diode (LED) display, including anorganic LED (OLED) display, or an organic electroluminescent (EL)display. The display may optionally be a touch pad or touch panel thatenables the user to input data into the memory of the power tool and/orthe battery pack via the adapter.

In such embodiments, the adapter is preferably configured or adapted todisplay information read from the memory of the power tool and/or thebattery pack. For example, the display of the adapter may visuallyindicate any of the information or functions described above or below,such as the present charge level (remaining battery capacity) of thebattery pack, an alarm indicating overheating, the predicted number offurther power tool operations that may be performed based upon theremaining battery capacity of the battery pack, the name of theadministrator of the power tool and the battery pack, the maximumcharged level, etc.

The display of the adapter may perform the same function as the displayof the external device, e.g., a smart phone, in the above- orbelow-described embodiments of the adapter enabled to performcommunication functions.

According to another exemplary embodiment according to the presentteachings, a “belt charger” is provided. In this example, the charger isconfigured to be worn or carried by the user while the user isperforming power tool operations. While it is presently envisioned thatthe charger will be worn on the user's belt, it could also be attachedto the user in various other locations. For example, the charger may beprovided with a harness or strap, which includes a detachable connector,such as a Velcro® connector, a hook-and-loop fastener, a clasp, asnap-fit connector, etc., configured to attach to the arm, leg or torsoof the user. In the alternative, the charger may be configured oradapted to be worn on the user's back, such as in a back pack or on aharness that fits over the user's shoulder(s).

Output power terminals of the charger (regardless of where the chargeris disposed on the user's body) are preferably disposed on or adjacentto a belt worn by the user, such as a work belt or tool belt typicallyworn when performing power tool operations. The output power terminalsare configured to transmit or output a charging current and mayoptionally be disposed in or on a hook engaging or receiving deviceconfigured or adapted to receive a belt hook disposed on a lateralsurface of the adapter or on the lateral surface of the battery pack inembodiments in which the adapter is omitted.

Input power terminals for receiving the charging current are disposed inor on the belt hook of the adapter or the battery pack in an arrangementthat is complementary to the output power terminals of the charger, i.e.so that the output power terminals contact the input power terminalswhen the user hangs the power tool on his/her belt using the belt hook.

Therefore, each time that the power tool is hung on the tool belt withthe input and output power terminals in contact, the adapter and/or thebattery pack is electrically connected to the charger, thereby enablingthe battery pack to be charged.

This embodiment is particularly advantageous with lithium-basedrechargeable batteries, which do not develop a “memory” after repeatedrecharging operations, unlike other types of battery chemistries, suchas nickel cadmium and nickel metal hydride. Therefore, no problemsresult by intermittently supplying charging current to the lithium-basedbattery, even if it is in a nearly fully charged state.

This embodiment also provides the advantage that the battery packattached to the power tool can be recharged every time that the powertool is not in use and is hung on the user's tool belt. Thus, the beltcharger embodiment can significantly extend the amount of time that thebattery pack can be used without requiring replacement for recharging,thereby improving worker productivity. In fact, if the user takesfrequent breaks between power tool operations, the battery pack may becontinuously maintained in a fully charged or nearly fully chargedstate.

In addition or in the alternative, this embodiment provides theadvantage that the charging of the battery cell(s) can be stopped at alower charge level or state (i.e. the upper charging limit or maximumcharging level can be decreased or set at a lower level), because thebattery cell(s) are frequently recharged and thus the energy (storedcharge) of the battery pack is not likely to be depleted during a normalpower tool operation. That is, if a battery pack is not recharged duringuse, the user may prefer to maximize the amount of stored charge (i.e.increase the upper charging limit or maximum charge level) during arecharging operation, so that the operating time of the power tool forone recharged battery pack can be maximized. However, when the batterycell(s) are repeatedly recharged to the maximum rated (nominal) chargestorage capacity of the battery cell(s), the service life of the batterycell(s) is negatively influenced. Therefore, by placing an upper limiton the charging that is less than the maximum rated (nominal) chargestorage capacity of the battery cell(s), the service life the batterycell(s) can be extended. Moreover, due to the frequent recharging of thebattery pack, the user is not inconvenienced by having to replace adepleted battery pack with a recharged battery pack, even though thebattery pack is never recharged to its maximum rated (nominal) chargestorage capacity.

The battery cell(s) of the charger may utilize a battery chemistryand/or capacity that differs from the battery chemistry and/or capacityof the battery cell(s) in the power tool battery pack. In particular,the charger battery is not required to deliver relatively high currents,as is the case for power tool battery packs. Thus, higher-capacitybattery cells may be used in the charger battery than in the power toolbattery pack, thereby increasing the charge storage density and/orreducing weight requirements for the charger. The charger battery ispreferably capable of storing an amount of charge (energy) equivalent toat least one complete recharging of the power tool battery pack, morepreferably at least five rechargings, even more preferably at least tenrechargings. Ergonomic considerations, such as the total weight of thebelt charger, and the battery chemistry (i.e. its charge storagedensity) will determine the appropriate balance of stored charge toweight. Naturally, the battery chemistry and/or capacity of the batterycell(s) of the charger may be same as the battery chemistry and/orcapacity of the battery cell(s) of the battery pack for the power tool.High capacity Li-ion cell(s) may be utilized in the charger and Highpower Li-ion cell(s) may be utilized in the battery pack.

In addition or in the alternative, the adapter of this embodiment neednot contain a microprocessor or other computing capabilities. Forexample, the battery pack or the power tool may include two sets ofbattery terminals. The first set of battery terminals is configured oradapted to engage the corresponding battery terminals of the power toolor the battery pack. The second set of battery terminals is configuredor adapted to engage the charging terminals of the charger. The secondset of battery terminals may be provided, e.g., on, in or adjacent to abelt hook, which may serve as the adapter in this embodiment. Thebattery terminals on the belt hook may then directly connect to thecharging terminals of the charger, which may be provided on a tool beltworn by the user. Thus, the charging current can be communicated fromthe charger to the battery pack via the belt hook adapter, which may bedirectly connected to the battery pack or the power tool.

In the alternative to the use of charging terminals for the charger andcorresponding battery terminals for the battery pack or the adapter,which require a direct or wired connection to communicate (conduct) thecharging current, it is also possible to wirelessly communicate powerfrom the charger to the battery pack. In such an embodiment, the chargermay include a wireless power transmitting antenna, such as an inductioncoil, which may be disposed, e.g., on the user's tool belt. The adaptermay include a wireless power receiving antenna, such as an inductioncoil, that is complementary to the wireless power transmitting antenna,so as to enable the wireless transmission of power using inductioncoupling or more preferably, resonant induction coupling.

In such an embodiment, when the wireless power receiving antenna isbrought into proximity with the wireless power transmitting antenna,power may be transmitted to the adapter or to the battery pack, inembodiments in which the adapter is omitted, in a wireless manner, e.g.,as an oscillating electromagnetic field or magnetic flux. The powerreceived by the adapter may then be converted into a current that issupplied to the battery cells of the battery pack. The adapter mayitself generate the appropriate charging current or the charging currentmay be generated within the battery pack, in particular in case theadapter is omitted.

This embodiment provides the advantage that the user is not required todirectly connect or contact the charging terminals with the batteryterminals in order to perform the charging operation. Instead, thecharging operation will automatically begin (if necessary) as long asthe wireless power receiving antenna of the adapter is brought intoproximity with the wireless power transmitting antenna of the charger. Aproximity sensing device, such as a mechanical contact, a pressuresensor, a radio frequency identification (RFID) device, a magnet (andmagnet sensor, such as a reed switch or a Hall sensor), an electricalresistance or capacitive sensor, etc. may be provided on or in one orboth of the adapter (or battery pack) and the charger, e.g., adjacent tothe power transmitting and receiving antennae. In this case, the chargerwill wirelessly transmit power only when charging current can becommunicated to the battery pack, thereby avoiding unnecessary waste ofpower.

As was mentioned above, it is reiterated that the adapter may beentirety omitted in such a wireless charging embodiment. For example,the wireless power receiving antenna may be provided on or in thebattery pack. In this case, when the wireless power receiving antenna ofthe battery pack is brought into proximity with the wireless powertransmitting antenna of the charger, e.g., by hanging the battery pack(connected to the power tool) on the user's tool belt, power may bewirelessly transmitted directly from the charger to the battery pack. Insuch an embodiment, the wireless power receiving antenna is preferablydisposed on the lateral side of the battery pack that includes a belthook, so that the charging operation will always begin when the belthook is hung on the user's tool belt adjacent to the wireless powertransmitting antenna. Therefore, the user is not required to take anyspecial measure to ensure that the battery pack is correctly orientatedon the tool belt in order to enable the charging operation.

In certain aspects of the present teachings, the adapter is preferablyat least partially disposed, located or accommodated within a spacebetween the housing and the battery pack when the housing and batterypack are attached to each other.

If the adapter of the above-noted aspect is at least partially disposed,located or accommodated between the housing and the battery pack, theadapter is physically protected by the housing and/or the battery pack,e.g. when the hand-held power tool is dropped or bumps againstsomething. Thus, this aspect of the present teachings provides a robustand durable structure for protecting the adapter in rugged workenvironments.

In a preferred embodiment of the above-noted aspect of the presentteachings, the battery pack is preferably adapted or configured to beattached to and detached from the housing regardless of whether theadapter is attached to or detached from the housing. The adapter of thisembodiment is preferably adapted or configured as an optional accessoryor device for the power tool and the adapter is preferably not necessaryfor normally operating the hand-held power tool (i.e. operating thepower tool without the additional function(s) performed or provided bythe adapter). Therefore, the battery pack can be attached to the housingto supply current to the hand-held power tool even when the adapter isdetached from the housing.

Furthermore, according to such a preferred embodiment, the power tooluser can detach the battery pack from the housing to charge the batterypack, and then reattach the (or another) charged battery pack to thehousing without having to detach the adapter from the housing. Thisembodiment is particularly advantageous for users who use the power toolfor relatively long durations (e.g., during an entire work day), becausein such applications of the present teachings it may be necessary toreplace a depleted battery pack with a charged battery pack severaltimes during the day.

In another preferred embodiment of the above-noted aspect of the presentteachings, the adapter is preferably adapted or configured to beattachable to and detachable from the housing only when the battery packis detached from the housing. With the adapter of this preferredembodiment, the power tool user can safely attach and detach theadapter, because the battery pack must be detached from the power toolin order to attach/detach the adapter such that no power is beingsupplied to either the hand-held power tool or the adapter while theadapter is being handled.

In another preferred embodiment of the above-noted aspect of the presentteachings, the adapter is preferably adapted or configured to beattached to and detached from the housing in a first direction, thebattery pack is preferably adapted or configured to be attached to anddetached from the housing in a second direction, and the first directionis substantially perpendicular to the second direction. More preferably,the adapter and battery pack are preferably adapted or configured to beslidably attached to and detached from the power tool housing.

In another preferred embodiment of the above-noted aspect of the presentteachings, the housing and the battery pack together define an openingtherebetween that visibly exposes at least a portion of the adapterwhile the adapter is attached to the housing (e.g., the opening isdefined through an outer surface of the hand-held power tool and/or thebattery pack).

With the adapter according to this preferred embodiment, the power tooluser can conveniently view the attached adapter (without having toremove it from the power tool or otherwise perform an inconvenientoperation to visually examine the adapter) in order to determine whichkind of adapter is attached to the power tool.

In another preferred embodiment of the above-noted aspect of the presentteachings, the adapter is preferably adapted or configured to fit in theopening with no significant clearance (e.g., with the minimum amount ofclearance necessary for manufacturing tolerance purposes) when theadapter and the battery pack are attached to the housing. In such anembodiment, dust and moisture may be prevented from entering into anyspace between the housing and the battery pack, thereby protecting thefirst and second connecters from negative outside influences.

In another preferred embodiment of the above-noted aspect of the presentteachings, the power tool system preferably further comprises a dummyadapter adapted or configured to be detachably attached to the housinginstead of the adapter. More preferably, the dummy adapter may bedesigned to fit in the opening with no substantial clearance when thedummy adapter and the battery pack are attached to the housing. In casethe power tool user does not require the use the (functional) adapter ofthe preceding aspects and/or embodiments, the user can insert the dummyadapter into the first (adapter) connector on the power tool housing inorder to prevent the ingress of dust and moisture into the first(adapter) connector.

In another preferred embodiment of the above-noted aspect of the presentteachings, the dummy adapter is preferably adapted or configured tocover the first connector when the dummy adapter is attached to thehousing. In this embodiment, the first connecter is protected from dustand moisture even when the battery pack is detached from the housing.

In another preferred embodiment of the above-noted aspect of the presentteachings, the first connecter is preferably a female connector thatcomprises at least one contact pin and a peripheral wall that surroundsthe at least one contact pin. In addition, the second connector ispreferably a male connector that comprises at least one hole configuredto receive the at least one contact pin and at least one contact platelocated within the at least one hole and adapted or configured tophysically and electrically contact the at least one contact pin.

With respect to this embodiment, it is noted that a female connectorgenerally costs less to manufacture than a male connector. Therefore, inorder to avoid increasing the manufacturing cost of the power tool, thepower tool may preferably employ a female connector (contact pin(s)),and the adapter may preferably employ a male connector (contactterminal(s)). Because the adapter is intended to be an optionalaccessory and some users may not require the adapter, this embodimentwill enable the manufacturing cost of the power tool to remain lower.

In another preferred embodiment of the above-noted aspect of the presentteachings, the adapter is affixable to the housing via a threadedfastener, e.g., a screw or a bolt. According to this embodiment, theadapter can be firmly affixed to the housing such that the connectionbetween the first and second connectors is stably and reliablymaintained.

In another preferred embodiment of the above-noted aspect of the presentteachings, the adapter is primarily positioned with respect to thehousing by the coupling of the first and second connectors and issecondarily positioned with respect to the housing by the tightenedthreaded fastener.

In another preferred embodiment of the above-noted aspect of the presentteachings, the adapter comprises a cylindrical portion, through whichthe threaded fastener is insertable in order to tighten and affix theadapter onto the power tool housing.

In addition, the cylindrical portion optionally may be exposed throughan outer surface of the power tool. In addition or in the alternative,the cylindrical portion optionally may be adapted or configured to beattached to a strap. In this embodiment, the cylindrical portion isreinforced by the threaded fastener that extends through the cylindricalportion, and is therefore prevented from breaking. In addition or in thealternative, a strap (e.g., a carrying strap) can be easily attached tothe adapter via the cylindrical portion.

In another preferred embodiment of the above-noted aspect of the presentteachings, the power tool system preferably comprises a plurality ofadapters, and each adapter is preferably adapted or configured to attachto the housing and to provide at least one different or additionalelectrical function to the hand-held power tool (i.e. an electricalfunction that the hand-held power tool does not inherently possess) orto perform at least one different or additional electrical function.

This embodiment enables a range of adapters to be made in order toimpart a variety of different electrical functions to the power tool. Itis noted that any of the electrical functions described in U.S.Provisional Application No. 61/511,092 or hereinbelow may be implementedin the adapters according to the present teachings, and thus, thedescription of all of the functions and circuitry mentioned in U.S.Provisional Application No. 61/511,092 is incorporated herein byreference.

In another aspect of the present teachings, the adapters may include, inaddition or in the alternative to the foregoing circuitry orfunctionality, an illuminating device, such as an incandescent lamp, afluorescent lamp and/or one or more light-emitting diodes. In such anembodiment, the illuminating device is preferably connected to a baseportion of the adapter via a flexible, but rigid cord that is capable ofpositioning or holding the illuminating device in an arbitrary positionrelative to the power tool housing, but preferably in the direction thatthe power tool is operating on a workpiece.

Representative, non-limiting examples or exemplary embodiments of thepresent invention will be described below in greater detail. Thisdetailed description is merely intended to teach a person of skill inthe art further details for practicing preferred aspects of the presentteachings and is not intended to limit the scope of the invention.Furthermore, each of the additional features and teachings disclosedabove may be utilized separately or in conjunction with other featuresand teachings to provide improved adapters, battery packs connected tosuch adapters, power tools connected to such adapters, power toolsystems, chargers and methods for manufacturing and using the same.

Moreover, combinations of features and steps disclosed in the followingdetailed description may not be necessary to practice the invention inthe broadest sense, and are instead taught merely to particularlydescribe representative examples of the invention. Furthermore, variousfeatures of the above-described aspects, features and representativeexamples, as well as the various independent and dependent claims below,may be combined in ways that are not specifically and explicitlyenumerated in order to provide additional useful embodiments of thepresent teachings.

All features disclosed in the description and/or the claims are intendedto be disclosed separately and independently from each other for thepurpose of original written disclosure, as well as for the purpose ofrestricting the claimed subject matter, independent of the particularcombination of features in the embodiments and/or the claims. Inaddition, all value ranges or indications of groups of entities areintended to disclose every possible intermediate value or intermediateentity for the purpose of original written disclosure, as well as forthe purpose of restricting the claimed subject matter.

It is expressly noted that all of the above- or below-described (orclaimed) functions may be implemented in any of the following exemplaryembodiments, e.g., by appropriately programming the controller(s) of theadapter, battery pack, power tool, charger and/or external device. Inthe alternative, some or all of the above-described functions may beimplemented in analog circuitry, dedicated digital circuitry, e.g., astate machine, or mixed dedicated circuitry in any of thebelow-described exemplary embodiments, as would be well understood by aperson of skill in the art after reading the present disclosure.

First Exemplary Embodiment

Referring to FIGS. 1A-1C, a first exemplary embodiment of a power toolsystem 1 according to the present teachings will now be described infurther detail. The power tool system 1 may generally comprise acordless (battery-powered) power tool 10, a battery pack 40, an adapter70 and an external device 100.

The power tool 10 according to this exemplary embodiment generallycomprises a controller 12, a discharge information detector 14, a memory16 and a communicator 18. Power is supplied to the power tool 10 via twobattery terminals 22 to drive the electric motor M by opening andclosing power FET 20, e.g., utilizing a pulse-width modulation techniqueas is well known in the art. The operation of the motor M is manuallycontrolled by a switch 28, which may be a trigger switch as is wellknown in the art. As shown in FIG. 1C, the motor M is enclosed in ahousing 32 and drives a tool chuck 30, to which an appropriate tool,e.g., a screw bit, may be connected. A reduction gear (not shown) mayoptionally be interposed between the motor M and the tool chuck 30.

The battery pack 40 according to this exemplary embodiment generallycomprises a controller 42, a charge/discharge information detector 44, amemory 46, a communicator 48 and at least one battery cell 50. Power issupplied to the power tool 10 via two battery terminals 52 to drive theelectric motor M. As shown in FIGS. 1A and 1C, a shut-off switch 58 maybe provided to disconnect the battery cell(s) 50 from the batteryterminals 52 in the event that the remaining battery capacity hasreached a lower limit, e.g., as determined by the controller 42, therebypreventing further use of the battery pack 40 until it has beenrecharged.

The adapter 70 according to this exemplary embodiment generallycomprises at least one controller 72, one or more communicationterminals (ports) 74, one or more power terminals 75, at least onememory 76 and at least one communicator 78. As will be further describedin the additional embodiments below, which are incorporated by referenceinto the present embodiment, the adapter 70 may further optionallyinclude a display.

The external device 100 generally comprises at least one controller 102,at least one display 104, at least one memory 106 and at least onecommunicator 108.

The controller(s) 12, 42, 72, 102 of each device preferably comprise(s)at least one processor, e.g., a microprocessor or microcontroller as iswell known in the art. The at least one processor is configured tooperate according to instructions or program code and data stored in thememory 16, 46, 76, 106, respectively.

The memory 16, 46, 76, 106 of each device preferably comprisesnon-volatile, read-only memory (ROM) and/or rewriteable memory, such asone or more EEPROMs and flash memory or mechanically addressable memory,such as a hard drive (e.g., in particular for the external device 100).The memory 16, 46, 76, 106 may also include volatile memory, such asRAM, DRAM and SRAM. The type and/or configuration of the memory 16, 46,76, 106 of any of the devices is not particularly limited according tothe present teachings.

The communicator(s) 18, 48, 78, 108 of each of the devices may comprise:(i) one or more wired input/output (I/O) ports (i.e. one or moreconnection terminals), (ii) a wireless communication device, such as awireless local area network (WLAN) device, e.g., WiFi (i.e. operatingaccording to the wireless communication protocol enumerated by IEEE802.11), a Bluetooth device, a cordless telephony or cellular (mobile)network device, a radio (RF) communication device or any other type ofknown or future-developed wireless communication technology, or both (i)and (ii). Again, the configuration of the communicator(s) 18, 48, 78,108 of any of the devices is not particularly limited according to thepresent teachings.

The adapter 70 is supplied with power via the power terminal(s) 25, 75.

The display (80—see FIG. 4A) of the adapter 70 and/or the display 104 ofthe external device 100 is also not particularly limited and may includeany device capable of visually communicating information to a user, suchas but not limited to a liquid crystal display (LCD), a light-emittingdiode (LED) display, including an organic LED (OLED) display, or anorganic electroluminescent (EL) display. Plasma or CRT are alsopossibilities for the display 104.

The discharge information detector 14 of the power tool 10 and thecharge/discharge information detector 44 of the battery pack 40 maycomprise any type of analog, digital or hybrid circuit configured todetect a current value, a voltage value, battery cell(s) temperatureand/or a resistive (impedance) value, as is well known in the art.

For example, in one exemplary embodiment, the charge/dischargeinformation detector 44 of the battery pack 40 may comprise a comparatorconfigured to compare a measured voltage value V (which may be thevoltage across the battery cells 50 or a voltage value indicative of thecurrent flow I across the battery cells 50) to a reference voltagevalue. The comparator may output a signal to the controller 42 in casethe voltage across the battery cells 50 falls below a predeterminedthreshold (as represented by the reference value), thereby providinginformation concerning the remaining battery capacity of the batterycells 50. In addition or in the alternative, the comparator may outputanother signal when the current across the battery cells 50 has exceededa predetermined current limit (threshold), thereby indicating that thepower tool system 1 is experiencing an overloaded condition. In additionor in the alternative, the comparator may output another signal when thetemperature (Temp.), e.g., as measured by a temperature sensor in thebattery pack 10 or power tool 10, has exceeded a predetermined atemperature limit (threshold), thereby also possibly indicating thebattery pack 40 or power tool system 1 is experiencing an overloadedcondition.

In addition or in the alternative, the discharge information detector 14of the power tool 10 may comprise a comparator configured to compare ameasured voltage value V, such as a voltage value indicative of thecurrent flow I across the electric motor M, to a reference voltagevalue. The comparator may output a signal to the controller 12 in casethe current across the motor M has exceeded a predetermined currentlimit (threshold), thereby indicating the power tool system 1 isexperiencing an overloaded condition. In addition or in the alternative,the comparator may output another signal when the temperature (Temp.),e.g., as determined by a temperature sensor, has exceeded apredetermined temperature limit (threshold), thereby also possiblyindicating the power tool 10 or power tool system 1 is experiencing anoverloaded condition.

Each of these thresholds may be stored in the memory 46 of the batterypack 40, the memory 16 of the power tool 10 and/or the memory 76 of theadapter 70. As was discussed above, one aspect of the present teachingsenables the user to change the various thresholds or operatingparameters, in order to optimize the performance of the battery pack 40and the power tool 10, by communicating a new threshold value via theadapter 70. In the alternative, the new value may be input directly intothe adapter 70 if the adapter 70 includes an input device, such as atouch pad, push button(s), keyboard, toggle switch, etc.

Thus, in one aspect of the present teachings, an operator (e.g., theuser, a tool administrator, a tool manager, etc.) may change one of thethresholds or operating parameters stored in the memory 16, 46 or 76 byinputting the new value into the external device 100 via an inputdevice, such as a keyboard or a display 104 configured as a touch pad.The communicator 108 transmits the new value, either wirelessly or via awired connection, to the communicator 78 of the adapter 70. As wasmentioned above, the new value may be stored in the memory 76 of theadapter 70 and optionally may be accessed by the battery controller 42via the power tool 10, or it may be accessed by the tool controller 12via the communication terminals 24, 74. If necessary, the new value maybe communicated to the battery pack 40 via communication terminals 26,56 and optionally also stored in the memory 46.

FIG. 1B identifies some additional functions that optionally may beperformed by, and additional features that optionally may be providedin, the respective devices or sub-units within each device. FIG. 1Cshows the exterior appearance of the power tool system 1 with cutawayviews to show some of the above-described interior circuit blocks.

Second Exemplary Embodiment

The second exemplary embodiment shares many overlapping features,functions, circuits and structures with the first exemplary embodiment.Therefore, circuits and structures that operate in the same orsubstantially the same way have been assigned the same reference numbersand a further description thereof is not necessary. Reference is made tothe first exemplary embodiment for any features, functions, circuits orstructures that are not expressly described in the second exemplaryembodiment, which are incorporated by reference into the presentembodiment.

The power tool system 1′ of the second exemplary embodiment shown inFIG. 2A primarily differs from the first exemplary embodiment in thatthe adapter 70′ is configured to directly connect to the battery pack40′, instead of directly connecting to the power tool 10′. The externaldevice 100 communicates with the adapter 70′ and operates in the sameway as the first embodiment.

Thus, in this exemplary embodiment, the communication path is asfollows: external device 100 to adapter 70′ to battery pack 40′ to powertool 10′. In particular, the adapter 70′ communicates information and/ordata via its communication terminal(s) 74 to the communicationterminal(s) 54 located on the battery pack 40′, which then communicatesdirectly with the controller 42 via the communicator 48.

However, in all other respects, the adapter 70′ may be configured oradapted to perform any one or any arbitrary combination of the functionsdescribed above or below.

FIG. 2B identifies some additional functions that optionally may beperformed by, and additional features that optionally may be providedin, the respective devices or sub-units within each device. FIG. 2Cshows the exterior appearance of the power tool system 1′ with cutawayviews to show some of the above-described interior circuit blocks.

The first and second exemplary embodiments provide the advantage thatthe adapter 70, 70′ is not interposed between the power tool 10, 10′ andthe battery pack 40, 40′. Therefore, it is not necessary to conduct themotor driving current from the battery pack 40, 40′ to the power tool10, 10′ via the adapter 70, 70′, thereby eliminating the need forproviding wiring capable of safely conducting large currents and otherprotections within the adapter 70, 70′.

However, in certain embodiments, it may be advantageous to interpose theadapter between the power tool and battery pack, as will be discussed inthe following exemplary embodiment.

Third Exemplary Embodiment

The third exemplary embodiment also shares many overlapping features,functions, circuits and structures with the first and second exemplaryembodiments. Therefore, circuits and structures that operate in the sameor substantially the same way have been assigned the same referencenumbers and a further description thereof is not necessary. Reference ismade to the first or second exemplary embodiment for any features,functions, circuits or structures that are not expressly described inthe third exemplary embodiment, which are incorporated by reference intothe present embodiment.

The power tool system 1″ of the third exemplary embodiment shown in FIG.3A primarily differs from the first and second exemplary embodiments inthat the adapter 70″ is configured to directly connect to both thebattery pack 40 and the power tool 10′. The external device 100communicates with the adapter 70″ and operates in the same way as thefirst and second exemplary embodiments.

Thus, in this exemplary embodiment, the external device 100 communicateswith the adapter 70″ and the adapter 70″ may communicate with one orboth of the battery pack 40 and the power tool 10′. In particular, theadapter 70″ may communicate information, such as new program code,and/or data via its communication terminal(s) 74 to the communicationterminal(s) 54 located on the battery pack 40 and/or via itscommunication terminal(s) 74 to the communication terminal(s) 24 locatedon the power tool 10′.

Furthermore, the current for driving the electronic motor M flowsthrough the adapter 70″ via its respective battery terminals 82 thatconnect with the battery terminals 52 of the battery pack 40 on one sideand with the battery terminals 22 of the power tool 10′ on the otherside.

However, in all other respects, the adapter 70″ may be configured oradapted to perform any one or any arbitrary combination of the functionsdescribed above or below.

FIG. 3B identifies some additional functions that optionally may beperformed by, and additional features that optionally may be providedin, the respective devices or sub-units within each device. FIG. 3Cshows the exterior appearance of the power tool system 1″ with cutawayviews to show some of the above-described interior circuit blocks.

Fourth Exemplary Embodiment

The fourth exemplary embodiment also shares many overlapping features,functions, circuits and structures with the first, second and thirdexemplary embodiments. Therefore, circuits and structures that operatein the same or substantially the same way have been assigned the samereference numbers and a further description thereof is not necessary.Reference is made to the first, second and third exemplary embodimentsfor any features, functions, circuits or structures that are notexpressly described in the fourth exemplary embodiment, which areincorporated by reference into the present embodiment.

The power tool system 1′″ of the fourth exemplary embodiment shown inFIG. 4A primarily differs from the first exemplary embodiment in thatthe adapter 70′″ includes a display 80, but does not include acommunicator dedicated to communicating with an external device. Thepower tool 10 and the battery pack 40 operate in the same way as thefirst embodiment. As will be understood, this embodiment also may bemodified to include communication means (e.g., wireless communicationmeans) according to any of the preceding embodiments.

As was mentioned above, the display 80 of the adapter 70′″ is notparticularly limited and may include any device capable of visuallycommunicating information to a user, such as but not limited to a liquidcrystal display (LCD), a light-emitting diode (LED) display, includingan organic LED (OLED) display, or an organic electroluminescent (EL)display. Preferably, the display 80 may be configured as a touch padthat enables the user to directly input instructions into the adapter70″. However, another type of input device (not shown), such as akeyboard, push button pad, toggle switch, etc., may optionally beprovided for inputting information into the adapter 70′″, if desired.

The display 80 preferably may be configured or adapted to display any ofthe information that was described above or below, such as but notlimited to, remaining battery capacity, number of additional power tooloperations that may be performed in view of the remaining batterycapacity, current limit threshold, battery discharge threshold, etc.

FIG. 4B identifies some additional functions that optionally may beperformed by, and additional features that optionally may be providedin, the respective devices or sub-units within each device. FIG. 4Cshows the exterior appearance of the power tool system 1′″ with cutawayviews to show some of the above-described interior circuit blocks.

Fifth Exemplary Embodiment

The fifth exemplary embodiment also shares many overlapping features,functions, circuits and structures with the first, second, third andfourth exemplary embodiments. Therefore, circuits and structures thatoperate in the same or substantially the same way have been assigned thesame reference numbers and a further description thereof is notnecessary. Reference is made to the first, second, third and fourthexemplary embodiments for any features, functions, circuits orstructures that are not expressly described in the fifth exemplaryembodiment, which are incorporated by reference into the presentembodiment.

The power tool system 1″″ of the fifth exemplary embodiment shown inFIG. 5A primarily differs from the second exemplary embodiment in thatthe adapter 70″ includes charging circuitry and a charger 120 is alsoprovided. The power tool 10′ and the battery pack 40′ generally operatein the same way as the second embodiment, except that the battery pack40′ is capable of receiving a charging current from the charger 120 viathe adapter 70″″. This exemplary embodiment also may be modified toinclude the (wireless) communication means and/or the display of any ofthe preceding exemplary embodiments.

As was described above with respect to the various charging embodiments,the adapter 70″″ according to this exemplary embodiment may generallyinclude at least one controller 72, at least one memory 76 and at leastone communicator 78. The controller 72 is configured or adapted toexecute at least a charging program or protocol stored in the memory 76or stored in the memory 46 and communicated to the controller 72 via thecommunication terminals 54, 74. The charging program is not particularlylimited according to the present teachings and any charging programsuitable for recharging the battery cell(s) 50 located in the batterypack 40′ may be utilized. Further, the controller 72 may be configuredto execute any of the other functions that are described above or below.

The charger 120 according to this exemplary embodiment includes at leastone controller 122, at least one memory 126, at least one communicator128 and a power source 130. The controller 122 also may execute thecharging program in case the charging program is stored in the memory126, e.g., after being communicated via the communication terminals 86,124 and the communicator 128, or based upon a charging program stored inthe memory 126 at the time of manufacture, or as programmed by anexternal device post-manufacture.

The battery pack 40′, adapter 70″″ and charger 120 each include acut-off switch 58, 88, 138 (see also FIG. 5C) controlled by therespective controller 42, 72, 122. The cut-off switch 58 may be closedto initiate power tool operations by the power tool 10′ and opened inorder to protect the internal circuitry in the event an overload orother adverse condition is detected. The cut-off switches 88, 138 may beclosed to initiate the charging operation and opened in order to protectthe internal circuitry in the event an overload or other adversecondition is detected, or when the charging operation is completed. Theadapter 70″″ may include a diode 90 to protect against reverse currentsthat may damage the internal circuitry.

The power source 130 may be an AC power supply, e.g., a commercial ACpower supply or an alternating current supplied by a generator, or anexternal DC power supply, such as a vehicle battery system. However, inpreferred embodiments, the power source 130 is a DC power supply 140that is contained within the charger 120 or is attached to the charger120, e.g., either directly or via a flexible power cord 142, as shown inFIG. 31. The power source 130 preferably includes one or morerechargeable battery cells, such as lithium-based battery cells, thatpreferably have a relatively high charge storage capacity, e.g., higherthan the charge storage capacity of the battery cells 50, as wasdescribed further above.

The power tool system 1″″ according to the present embodiment may beoperated according to the “belt charging” embodiment that was describedabove. Referring further to FIG. 31, the charger 120 includes the DCpower supply 140 that can be carried by the user while working. A meansfor attaching the charger 120 to the user, such as a belt 144, oralternatively a harness, strap, backpack, etc., may be utilized so thatthe user can easily and comfortably wear or carry the charger 120 onhis/her body, e.g., a limb or on the torso or back. The chargingterminals 132 (not shown in FIG. 31) are preferably provided on the belt140 in or on a belt hook receiver 146 that will be described furtherbelow.

Referring again to FIG. 5A, the adapter 70″″ preferably includes aportion that directly connects to the battery pack 40′ via the chargingterminals 84. The charging terminal receivers 85 are configured todirectly connect to the charging terminals 132 of the charger 120 andare preferably disposed in or on a belt hook, which will be furtherdescribed and shown below with respect to the sixth exemplaryembodiment. The belt hook and the belt hook receiver 146 are preferablyconfigured in complementary shapes so as to engage in an interlocking,interference or form-fit when the user hangs the power tool 10′ onhis/her tool belt 144 by engaging the belt hook on the adapter 70″″ (oron the battery pack 40′) with the belt hook receiver 146.

When the terminals 85, 132 are in contact and thus are capable ofconducting charging current from the charger 120 to the battery pack 40′via the adapter 70″″, one or more of the controllers 42, 72, 122 maysense or detect the connection so as to initiate the supply of chargingcurrent. When the terminals 85, 132 are separated, e.g., because theuser has removed the power tool 10′ from his/her tool belt 144, one ormore of the controllers 42, 72, 122 may sense or detect thedis-connection so as to terminate the supply of charging current,thereby saving power.

In addition, the charge detector 44 may continuously or intermittentlysense the charge state of the battery cells 50 during the chargingoperation. When the battery cells 50 are determined to be fullyrecharged, the controller 42 of the battery pack 40′ may transmit asignal to the adapter 70″″ and/or to the charger 120 to stop the supplyof charging current, thereby avoiding power waste.

As was described above, the adapter 70″″ of this embodiment need notinclude the charger controller 72, memory 76 or communicator 78.Instead, the adapter 70″″ may be configured simply as the belt hook thatis physically connected to the battery pack 40′ and includes thecharging terminal receivers 85 configured to directly connect to thecharging terminals 132. The belt hook thus only serves to conduct thecharging current from the charger 120 to the battery pack 40′ and is notrequired to perform any other functions.

Furthermore, as was described above, it is not necessary to communicatethe charging current (power) from the charger 120 to the adapter 70″″via a wired or direct connection. Instead, the charging terminals 132 ofthe charger 120 may be replaced with a wireless power transmittingantenna, such as an induction coil, and the charging terminal receivers85 of the adapter 70″″ (or belt hook) may be replaced with a wirelesspower receiving antenna, such as an induction coil. In this case, whenthe wireless power receiving antenna is brought into proximity with thewireless power transmitting antenna, e.g., as detected by a proximitysensor, such as a pressure sensor, a magnetic sensor, an RFID device(tag and interrogator), an electrical resistive or capacitive sensor,etc., the wireless power transmitting antenna of the charger 120 maybegin to emit a varying or oscillating electromagnetic field, e.g., amagnetic flux, that causes a current to flow in the wireless powerreceiving antenna of the adapter 70″″. This current may then beconverted into an appropriate charging current that is supplied to thebattery cell(s) 50.

This embodiment is advantageous in that the wireless power transmittingantenna need only be brought into proximity with the wireless powerreceiving antenna in order to perform the charging operation, which maybe more convenient for the user, because it eliminates the necessity ofensuring that the charging terminal receivers 85 on or in the belt hookare properly engaged with the charging terminals 132 on or in the belthook receiver 146.

This wireless embodiment may also be implemented using the complementarybelt hook and belt hook receiver 146 for housing the wireless powerreceiving antenna and the wireless power transmitting antenna,respectively. In this case, when the user places the power tool 10′ onhis/her tool belt 144, by placing the belt hook disposed on the adapter70″″ or battery pack 40′ in or on (i.e. at least adjacent to or inproximity with) the belt hook receiver 146, a proximity sensor maydetect the presence of the belt hook and cause the charger 120 to beginwirelessly transmitting power, e.g., by applying an oscillating currentto the wireless power transmitting antenna (e.g., an induction coil).

As was described above, the adapter 70″″ of this wireless embodimentalso need not include the controller 72, memory 76 or communicator 78.Instead, the adapter 70″″ may be configured simply as the belt hook thatis physically connected to the battery pack 40′ and includes thewireless power receiving antenna (e.g. an induction coil) for absorbingor taking the power being wirelessly transmitted by the charger 120. Thebelt hook may also include basic circuitry for supplying a current tothe battery pack 40′. The controller 42 of the battery pack 40 mayexecute a charging program stored in the memory 46 for recharging thebattery cell(s) 50. The belt hook thus only serves to supply a currentto the battery pack 40′ and is not required to perform any otherfunctions.

Further teachings concerning the wireless transmission of power forcharging a power tool battery are provided in a U.S. provisionalapplication No. 61/511,089, the contents of which are incorporated byreference as if fully set forth herein.

FIG. 5B identifies some additional functions that optionally may beperformed by, and additional features that optionally may be providedin, the respective devices or sub-units within each device. FIG. 5Cshows the exterior appearance of the power tool system 1″″ with cutawayviews to show some of the above-described interior circuit blocks.

Sixth Exemplary Embodiment

The sixth exemplary embodiment also shares many overlapping features,functions, circuits and structures with the first, second, third, fourthand fifth exemplary embodiments. Therefore, circuits and structures thatoperate in the same or substantially the same way have been assigned thesame reference numbers and a further description thereof is notnecessary. Reference is made to the first, second, third, fourth andfifth exemplary embodiments for any features, functions, circuits orstructures that are not expressly described in the sixth exemplaryembodiment, which are incorporated by reference into the presentembodiment.

The power tool system 1′″″ of the sixth exemplary embodiment shown inFIG. 6A primarily differs from the fifth exemplary embodiment in thatthe adapter 70′″″ is configured to connect to the power tool 10, similarto the first exemplary embodiment described above. The power tool 10 andthe battery pack 40 generally operate in the same way as the firstexemplary embodiment, except that the battery pack 40 is capable ofreceiving a charging current from a charger 120 via the adapter 70′″″and the power tool 10. Again, this exemplary embodiment also may bemodified to include the (wireless) communication means and/or thedisplay of any of the preceding exemplary embodiments.

Furthermore, the charger 120 and adapter 70′″″ may operate in the samemanner as described above with respect to the fifth exemplaryembodiment, such that it is not necessary to repeat the entiredescription of the charger 120 and adapter 70′″″ in the presentembodiment. Rather, the teachings of the fifth exemplary embodiment areincorporated entirely into the present embodiment.

Referring to FIGS. 32A-C, the charging terminal receivers 85 of theadapter 70′″″ are configured to directly connect to the chargingterminals 132 of the charger 120 (disposed on the belt hook receiver 146shown in FIG. 31) and are preferably disposed in or on a belt hook 148.As was described above, the belt hook 148 and the belt hook receiver 146are preferably configured in complementary shapes so as to engage in aninterlocking, interference or form-fit when the user hangs the powertool 10′ on his/her tool belt 144 by engaging the belt hook 148 on theadapter 70″″ (or on the battery pack 40′) with the belt hook receiver146.

FIG. 6B identifies some additional functions that optionally may beperformed by, and additional features that optionally may be providedin, the respective devices or sub-units within each device. FIG. 6Cshows the exterior appearance of the power tool system 1′″″ with cutawayviews to show some of the above-described interior circuit blocks.

While the fifth and sixth exemplary embodiments illustrate the chargingfunction being performed by connecting the adapter to only one of thepower tool or the battery pack, of course, the charging function mayalso be implemented in an adapter that connects to both the power tooland the battery pack, similar to the fourth exemplary embodiment.Therefore, an embodiment is expressly understood as falling within thescope of the present teachings, in which an adapter is interposedbetween the power tool and the battery pack and contains the chargingfunctionality described in the fifth and sixth exemplary embodiments.

Seventh Exemplary Embodiment

FIG. 7 shows the outer appearance of a representative power tool systemaccording to a seventh exemplary embodiment of the present teachings,which is a further development of the above-described first exemplaryembodiment. Therefore, where appropriate, the same reference numbers forthe same elements as in the first exemplary embodiment will be used inthe seventh exemplary embodiment and the description thereof isincorporated by reference into the seventh exemplary embodiment.

The power tool system 1 shown in FIG. 7 comprises a hand-held power tool10 and a battery pack 40. The battery pack 40 is configured to bedetachably attached to a battery pack interface 34 provided on the powertool housing 32. The attached battery pack 40 supplies current to thepower tool 10, e.g., to an electric motor M contained therein, whichserves as an electrically-driven device, although otherelectrically-driven devices are possible with the present teachings,such as e.g., lights, radios, etc.

FIG. 8 shows a rear view of the battery pack interface 34 with anadapter 70 provided for this power tool system 1. The adapter 70 islocated between the power tool housing 32 and the battery pack 40. Theadapter 70 shown in FIG. 8 is a wireless communication adapter (as wasdescribed in more detail above), which is an example of a relativelysmall-sized adapter. In this embodiment, the entire adapter 70 islocated between the power tool housing 32 and the battery pack 40, suchthat none (no part) of the adapter 70 projects or protrudes beyond theouter surface or contour of the power tool housing 32 and battery pack40.

Further, the power tool 10 and the battery pack 40 are configured suchthat an opening 36 visibly exposes at least a portion of the adapter 70so that the power tool user can visually examine in a convenient mannerwhich kind of the adapter (i.e. which functionality it provides) ispresently attached to the power tool 10. A specific indication such as aname, a letter or code, e.g. “1”, may be provided on the outer surfaceof the communication adapter 70 to indicate the kind of the adapter.

FIG. 9 shows a bottom view of the battery pack interface 34 defined orprovided on the power tool housing 32 without the battery pack 40attached thereto. The adapter 70 is configured to be detachably attachedto the power tool housing 32. In this embodiment, both the battery pack40 and the adapter 70 may be attached to the power tool housing 32 suchthat the adapter 70 is not directly connected to the battery pack 40.Furthermore, the battery pack 40 can be attached to the power toolhousing 32 (i.e. to the battery pack interface 34 thereof), and thus tosupply current to the power tool 10, regardless of whether the adapter70 is present (connected) or not.

FIG. 10 shows the adapter 70 detached from the power tool housing 32. Inthis embodiment, the adapter 70 is attached to and detached from thebattery pack interface 34 via the lower or bottom side thereof.Therefore, in this embodiment, it is possible to attach and detach theadapter 70 only when the battery pack 40 is detached (separated) fromthe power tool 10. Accordingly, users can safely attach the adapter 70to (and detach it from) the power tool housing 32, because the batterypack 40 is detached and thus no power is being supplied to the powertool 10 and the adapter 70.

Further, the lower side of adapter 70 is supported by the battery pack40. Therefore, the adapter 70 is prevented from being unexpectedly orunintentionally detached from the power tool housing 32. As shown inFIGS. 8 and 10, the adapter 70 optionally may be affixed to the housing32 with a threaded fastener 92, e.g., a screw or a bolt. In thealternative, a rod-shaped latching device may be inserted through ahollow cylinder portion 91 (described further below) and may be coupledto the power tool housing 32 by an interference-fit or a connectionother than a threaded connection.

FIG. 11 shows the representative example of the wireless communicationadapter 70 in isolation. This adapter 70 includes a male connector 94configured to connect with the power tool 10. The male connector 94 ofthe adapter 70 has holes 96 (an example of “at least one hole”) andcontact terminals 97 are disposed on respective projecting bodies 98 inthe hole(s) 96. The adapter 70 further includes the hollow cylindricalportion 91, which receives the threaded fastener 92 therethrough forfastening or affixing the adapter 70 to the power tool housing 32. Aswill be further described below, the cylindrical portion 91 also servesas a strut or bracket for attaching a strap 150.

Furthermore, as shown in FIGS. 10 and 11, the adapter 70 may includeribs 93 disposed on opposite lateral sides thereof. The ribs 93 may beslid into corresponding slots 33 defined in the power tool housing 32 inorder to provide more structural support for the adapter 70 when it isattached to the power tool 10.

FIG. 12 shows the battery pack interface 34 without the adapter 70, suchthat a space 35 between the power tool housing 35 and the battery pack40 for receiving at least a portion of the adapter 70 can be seen. Afemale connector 37 is provided within the battery pack interface 34 andis configured to receive (engage) the male connector 94 of the adapter70. The female connector 37 includes contact pins 38 disposed inside aconcave portion defined by a peripheral wall 39. When the femaleconnector 37 receives the male connector 94 of the adapter 70, thecontact pins 38 of the female connector 37 enter into the holes 96 ofthe male connector 94, thereby physically and electrically contactingwith the contact terminals 97 of the male connector 94. The peripheralwall 39 of the female connector 37 surrounds the contact pins 38 toprevent the contact pins 38 from contacting the user's fingers or otherobjects.

FIGS. 13-15 show cross-sectional and cutaway views through therepresentative power tool system comprising the power tool housing 32,the adapter 70 and the battery pack 40. FIGS. 13-15 thus show how theadapter 70 can be disposed entirely within the shell of the power toolsystem, so that no portion of the adapter 70 extends beyond an outercontour of the power tool housing 32 and/or an outer contour of thebattery pack 40. However, it will be understood that the adapter 70 maybe modified so that it partially or even substantially extends beyondthe outer contour of the power tool housing 32 and/or the outer contourof the battery pack 40.

FIG. 16 shows a cutaway view of the battery pack interface 34 withcertain elements of the power tool 10 omitted for clarity purposes.

As shown in FIGS. 13-16, the power tool 10 includes an electronic unit11 with a circuit board 13. The female connector 37 may be formedintegrally with the electronic unit 11 and the contact pins 38 extendfrom the circuit board 13. Similarly, the adapter 70 is also providedwith a circuit board 73 and its contact terminals 97 are disposed on thecircuit board 73.

In the lateral cross-section shown in FIG. 13, the connection of themale connector 94 and the female connector 37 can be seen in greaterdetail. In particular, the vertically-extending contact pins 38 areshown in contact with the contact terminals 97, thereby establishing acommunication path between the power tool 10 (in particular a controller12 disposed therein) and the adapter 70 (in particular, a controller 72disposed therein), as were previously described above with theassistance of FIGS. 1A-1C and will be further described below with theassistance of FIG. 28.

The electronic unit 11 of the power tool 10 preferably includes thecontroller 12, memory 16, communicator 18, etc., which execute theelectronic functions of the power tool 10. One or more of theseelectronic circuits is preferably mounted on the circuit board 13.

FIGS. 14 and 15 show lateral cross-sections through the adapter 70 asviewed from the front of the power tool housing 32. The electricalconnections between the contact terminals 97 and the contact pins 38 canbe easily seen.

In FIG. 16, the electronic unit 11 of the power tool 10 can be seendisposed above the battery pack 40 and the adapter 70. The contact pins38 are exposed. As will be discussed further below, a strap 150optionally may be attached to the adapter 70 via the cylindrical portion91.

FIG. 17 shows the electronic unit 11 removed from the power tool 10 forclarity purposes. The female connector 37 may be integrally formed withthe electronic unit 11. The peripheral wall 39 surrounds the contactpins 38.

Eighth Exemplary Embodiment

FIGS. 18-20 show another representative embodiment of an adapter 70′″according to the present teachings, which is a further development ofthe above-described fourth exemplary embodiment. Therefore, whereappropriate, the same reference numbers for the same elements as in thefourth exemplary embodiment will be used in the eighth exemplaryembodiment and the description thereof is incorporated by reference intothe eighth exemplary embodiment.

This adapter 70′″ is a display adapter that includes a display 80, whichis an example of a medium-sized adapter. Such an adapter 70′″ ispartially located or disposed outside of the power tool housing 32 (i.e.a part of the adapter 70′″″ projects from the outer wall or outercontour of the power tool housing 32 and/or the battery pack 40).

The display adapter 70′″ also may comprise the male connector 94, thecylindrical portion 91 and the ribs 93 according to the precedingembodiment. That is, the attachment structure may be identical to theattachment structure provided on the wireless communication adapter 70.Moreover, a specific indication such as a name, a letter or a code, e.g.“2”, also may be provided on the outer surface of the display adapter70′″ to indicate the kind of the adapter.

While the display 80 is preferably an LCD (liquid crystal display), thepresent teachings are not particularly limited in this regard and othertypes of display technologies may be advantageously utilized with thepresent teachings as is described above and claimed below.

The electronic functions of the adapter 70′″″ may be executed by thecircuits shown in FIGS. 4A-4C above, or as will be described with theassistance of FIG. 29 below.

Ninth Exemplary Embodiment

FIGS. 21 and 22 show another representative embodiment of an adapter70″″″ according to the present teachings. This adapter 70″″″ is alighting adapter having a light 152 supported by a flexible arm 154,which is an example of a large-sized adapter. Such an adapter 70″″″ isalso partially located outside of the power tool 10, similar to thepreceding embodiment. The lighting adapter 70″″″ may include the commonattachment structure, i.e. the male connector 94, the cylindricalportion 91 and the ribs 93, according to the preceding embodiments. Aspecific indication such as name, a letter or a code, e.g. “3”, is alsoprovided on the outer surface of the lighting adapter 70″″″ to indicatethe kind of the adapter.

The flexible arm 154 is preferably flexible to permit the illuminationdirection of the light 152 to be changed by the user, but is also rigidso as to maintain the light 152 in the desired direction after it hasbeen set by the user. A manual ON/OFF switch 156 may be provided on theexterior of the adapter 70″″″ to permit the user to selectivelyilluminate the light 152.

The electronic functions of the adapter 70′″″ may be executed by thecircuits that will be described with the assistance of FIG. 30 below.

Although the light 152 is preferably embodied as one or more LEDs, otherillumination technologies may be used interchangeably with this aspectof the present teachings, such as incandescent and fluorescent lights.

Tenth Exemplary Embodiment

FIGS. 23-25 show a dummy adapter 170. The dummy adapter is a plasticpart that has a similar outer shape or contour as the preceding adapters(all of which are capable of performing at least one electricalfunction). On the other hand, the dummy adapter 170 may be attached tothe power tool housing 32 to replace the functional adapter. Thus, whenthe user does not require any functional adapter to be inserted in theslot for the adapter, the dummy adapter 170 can be attached to the powertool 10. The dummy adapter 170 fits into the opening 36 formed on theouter surface of the power tool 10 to prevent the ingress of dust andmoisture. Further, the dummy adapter 170 may include a dummy maleconnector 94 that can be coupled with the female connector 37 of thepower tool 10 to protect it and the contact pins 38. The dummy adapter170 also may include the cylindrical portion 91 for affixing the dummyadapter 170 to the power tool housing 32 via the threaded fastener 92.

Eleventh Exemplary Embodiment

FIGS. 26 and 27 shows a strap 150 attached to the cylindrical portion 91of any one of the adapters 70, etc. according to any precedingembodiment. The user can attach the strap 150 to the cylindrical portion91 and easily replace it by detaching the adapter 70, etc. In order toflexibly or pivotably support the strap 150, a space is formed betweenthe cylindrical portion 91 and the power tool housing 32. Because thethreaded fastener 92 extends through the hollow cylindrical portion 91,the cylindrical portion 91 is reinforced against breakage.

FIG. 28 shows a representative circuit diagram of the battery pack 40,the power tool 10 and the wireless communication adapter 70 according tothe seventh exemplary embodiment. This circuit provides the same basicelectronic functions as the circuits and diagrams shown in FIGS. 1A-1C.Therefore, the same elements in FIGS. 1A-1C have been provided with thesame reference numerals in FIG. 28 and the description thereof isincorporated into the present embodiment by reference. Reference is madeto the description associated with FIGS. 1A-1C above for description ofany elements shown in FIG. 28, but not explicitly described in thefollowing.

The adapter 70 comprises an MPU (microprocessor unit) or CPU 72 and anRF (radio frequency) module 78 that are in electronic communication. Thecommunication terminals 74 of the adapter 70, i.e. the “+”, “SW”, “Tx”,“Rx”, “BS” and “−” terminals, correspond to or are comprised of thecontact terminals 97 provided on the male connector 94. Correspondingly,the communication terminals 24 of the power tool 10, i.e. the “+”, “SW”,“Rx”, “Tx”, “BS” and “−” terminals, correspond to or are comprised ofthe contact pins 38 provided on the female connector 37. Thecommunication adapter 70 is electrically connected to the battery pack40 via the power tool 10. The MPU 72 of the adapter 70 communicates withan MPU 42 of the battery pack 40 via an MPU 12 of the power tool 10. RFsignals generated by the RF module (communicator) 78 are wirelesslytransmitted to an external device (in accordance with theabove-described embodiments) via an antenna 79.

It should be understood that, although wireless communication adaptershave been disclosed above, it is also possible to provide wiredcommunication adapters. In this case, the RF module 78 is replaced witha wired connector, such as any kind of plug and socket connector knownin the art that can provide serial or parallel communications between aprocessor in the power tool and/or battery pack and a processor in anexternal device (e.g., a computing bus), including but not limited to aUSB connector.

FIG. 29 shows a representative circuit diagram of the battery pack 40,the power tool 10 and the display adapter 70′″ according to the eighthexemplary embodiment. This circuit provides the same basic electronicfunctions as the circuits and diagrams shown in FIGS. 4A-4C. Therefore,the same elements in FIGS. 4A-4C have been provided with the samereference numerals in FIG. 29 and the description thereof isincorporated into the present embodiment by reference. Reference is madeto the description associated with FIGS. 4A-4C above for description ofany elements shown in FIG. 29, but not explicitly described in thefollowing.

The display adapter 70′″ comprises an MPU (or CPU) 72, an LCD Control IC(integrated circuit) or LCD driver 81 and an LCD panel 80. The LCD panel80 may be driven by the LCD driver 81 based upon video signals generatedby the MPU 72 in a manner well known in the art.

FIG. 30 shows a representative circuit diagram of the battery pack 40,the power tool 10 and the lighting adapter 70″″″ according to the ninthexemplary embodiment. The lighting adapter 70″″″ comprises an MPU or CPU72, a plurality of LEDs 153, a constant current circuit (e.g., a currentregulator) 155 and a manual ON/OFF switch 156. When the manual switch156 is activated, the MPU 72 turns on an FET 158 in order to illuminatethe LEDs 153. The constant current circuit 155 adjusts the brightness ofthe LEDs 153 by changing the amount of current that flows through theLEDs 153 according to instructions from the MPU 72 in a manner wellknown in the art.

The remaining circuits and elements of FIG. 30 operate in the samemanner as the above-described FIGS. 28 and 29 and therefore need not berepeated again.

Although lithium-based battery cells are presently preferred for use inthe adapters and chargers of the present teachings, in particularlithium ion battery cells, the present teachings are not particularlylimited in this regard and any other suitable battery chemistry may beutilized, such as, e.g., lithium metal oxide, lithium polymer, lithiummetal phosphate, lithium sulfur, lithium sulfide and lithium sulfate.

Furthermore, although elements 91-94 have been described has onesuitable means for engaging the adapter 70, 70′″, 70″″, 70′″″ with thepower tool 10, the present teachings are not particularly limited inthis regard. For example, various other interlocking, form-fit,press-fit or fastener connections may be interchangeably utilized withthe present teachings to physically engage the adapters with the powertool and/or with the battery pack, such as one or more slide rails, aplug-and-socket arrangement, other types of threaded connections (e.g.,screw or bolt fastening the adapter to an outer or inner portion of thepower tool housing and/or to the battery pack), one or more clamps, oneor more clasps, etc. In short, any type of element or set of elementscapable of detachably connecting the adapter to the power tool housingand/or to the battery pack should be understood as falling within theexpression “means for detachably connecting” to the battery pack and/orthe power tool.

Further embodiments disclosed herein include, but are not limited to:

1. An adapter for a power tool powered by a detachable battery pack,comprising:

means for detachably connecting to only the power tool,

a controller, such as at least one microprocessor,

at least one memory or storage device in communication with thecontroller, and

at least one communication port configured to electrically communicatewith a controller, such as at least one microprocessor, located in thepower tool.

2. The adapter according to embodiment 1, wherein when a battery pack isconnected to the power tool, which battery pack includes a controller,such as at least one microprocessor, a communication path is establishedsuch that the battery pack controller communicates with the adaptercontroller via the power tool controller.

3. An adapter for a power tool powered by a detachable battery pack,comprising:

means for detachably connecting to only the battery pack,

a controller, such as at least one microprocessor,

at least one memory or storage device in communication with thecontroller, and

at least one communication port configured to electrically communicatewith a controller, such as at least one microprocessor, located in thebattery pack.

4. The adapter according to embodiment 3, wherein when a battery pack isconnected to the power tool, which power tool includes a controller,such as at least one microprocessor, a communication path is establishedsuch that the power tool controller communicates with the adaptercontroller via the battery pack controller.

5. An adapter for a power tool powered by a detachable battery pack,comprising:

first means for detachably connecting to the battery pack,

second means for detachably connecting to the power tool,

a controller, such as at least one microprocessor,

at least one memory or storage device in communication with thecontroller,

at least one first communication port configured to electricallycommunicate with a controller, such as at least one microprocessor,located in the battery pack, and

at least one second communication port configured to electricallycommunicate with a controller, such as at least one microprocessor,located in the power tool.

6. The adapter according to embodiment 5, wherein when the adapter isconnected to the battery pack and to the power tool, a communicationpath is established such that the battery pack controller communicateswith the adapter controller and the adapter controller communicates withthe power tool controller.

7. The adapter according to any preceding embodiment, wherein theadapter is configured or adapted to measure the remaining batterycapacity of the battery pack.

8. The adapter according to any preceding embodiment, wherein theadapter is configured or adapted to measure a discharge voltage ofbattery cells located in the battery pack.

9. The adapter according to embodiment 7 or 8, wherein the adapter isfurther configured or adapted to estimate a number of additional powertool operations that can be performed based upon the measured remainingbattery capacity and/or the measured discharge voltage of the batterycells.

10. The adapter according to embodiment 9, wherein the at least onememory stores a set of energy values corresponding to a plurality ofpower tool operations and the controller is configured or adapted tocalculate the number of additional power tool operations that can beperformed based upon the measured remaining battery capacity and/or themeasured discharge voltage of the battery cells by dividing the measuredremaining battery capacity by the stored energy value corresponding tothe currently performed power tool operation.

11. The adapter according to embodiment 9 and 10, wherein:

at least one of the adapter, power tool or battery pack is furtherconfigured or adapted to dynamically measure the amount of energyconsumed during the performance of a power tool operation and

the adapter controller is configured to calculate the number ofadditional power tool operations of the same type that can be performedbased upon the measured remaining battery capacity and/or the measureddischarge voltage of the battery cells by dividing the measuredremaining battery capacity by the measured amount of energy consumedduring the power tool operation.

12. The adapter according to embodiment 11, wherein the adaptercontroller is configured to:

store in the memory the measured amount of consumed energy for aplurality of power tool operations and

calculate the number of additional power tool operations by dividing themeasured remaining battery capacity by an average or a mean of themeasured amount of consumed energy for the plurality of power tooloperations.

13. The adapter according to any preceding embodiment, wherein theadapter is configured or adapted to change one or more operatingparameters stored in a memory of the battery pack and/or the power tool,such as a value for a maximum current limit.

14. The adapter according to embodiment 13, wherein the adapter isconfigured or adapted to receive instructions concerning the changedoperating parameter(s) from an external device.

15. The adapter according to any preceding embodiment, wherein theadapter is configured or adapted to store, display and/or transmit,e.g., to an external device, maintenance information concerning thepower tool and/or the battery pack.

16. The adapter according to embodiment 15, wherein the maintenanceinformation is one or any arbitrary combination of:

(i) a date of a last maintenance check/inspection,

(ii) the result of the last maintenance check/inspection,

(iii) the accumulated or total usage (operation) time of the power tooland/or the battery pack,

(iv) the available charge or charge status (remaining battery capacity)of the battery pack,

(v) the number of charging cycles experienced by the battery pack,

(vi) the condition of one or more battery cells in the battery pack,e.g., as calculated from an internal impedance measurement of thebattery cell(s),

(vii) the expected remaining service life of one or more replaceableparts in the power tool and/or the battery pack,

(viii) a maintenance schedule for the power tool and/or the adapterand/or the battery pack,

(ix) a usage history of the power tool and/or the adapter and/or thebattery pack,

(x) the name(s) of an administrator or responsible person for the tool,

(xi) a serial number of the battery pack and/or the power tool,

(xii) the voltage of one or more (e.g., either individually or asummation of two or more) battery cell(s),

(xiii) the discharge current of one or more (e.g., either individuallyor a summation of two or more) battery cell(s),

(xiv) the temperature of one or more (e.g., either individually or asummation of two or more) battery cell(s),

(xv) the number of times that the battery pack and/or the power tool hasbeen switched ON and/or OFF, and/or

(xvi) the amount of charging or discharging that has occurred within apredetermined time period (e.g., the amount of discharged power duringthe previous 2 hours).

17. The adapter according to embodiment 15 or 16, wherein the adapter isconfigured or adapted to enable the external device to access themaintenance information stored in the adapter.

18. The adapter according to any preceding embodiment, wherein theadapter is configured or adapted to dynamically detect a dischargecurrent supplied to an electronic motor of the power tool duringoperation and to store the detected discharge current.

19. The adapter according to embodiment 18, wherein the adapter isfurther configured or adapted to compare the detected discharge currentto an upper discharge current limit and/or to a lower discharge currentlimit, and to optionally use the comparison result to recommend adifferent power tool for performing a power tool operation.

20. The adapter according to embodiment 18 or 19, wherein the adapter isfurther configured or adapted to transmit the detected discharge currentand/or the power tool recommendation to an external device.

21. The adapter according to any preceding embodiment, wherein theadapter is configured or adapted to change a maximum charged level ofthe battery pack.

22. The adapter according to any preceding embodiment, wherein theadapter is configured or adapted to perform an anti-theft function.

23. The adapter according to embodiment 22, wherein the anti-theftfunction includes communicating a key transmitted from an externaldevice to an electronic lock located in the battery pack and/or in thepower tool.

24. The adapter according to any preceding embodiment, wherein theadapter memory is configured or adapted to store information concerninga person responsible for administering or managing the adapter, batterypack and/or power tool.

25. The adapter according to any preceding embodiment, wherein theadapter is configured or adapted to change a charging speed of thebattery pack, e.g., based upon an instruction manually input into theadapter or based upon an instruction transmitted by an external device.

26. The adapter according to embodiment 25, wherein the instructionincludes increasing the charging current and/or increasing a batterypack temperature threshold.

27. The adapter according to any preceding embodiment, wherein theadapter is configured or adapted to measure one or more valuesindicative of the operational state of the battery pack and/or the powertool, such as a temperature, current and/or voltage.

28. The adapter according to embodiment 27, wherein the adapter isfurther configured or adapted to display the value(s) indicative of theoperational state of the battery pack and/or the power tool.

29. The adapter according to embodiment 27 or 28, wherein the adapter isfurther configured or adapted to transmit the value(s) indicative of theoperational state of the battery pack and/or the power tool to anexternal device.

30. The adapter according to any preceding embodiment, furthercomprising:

means for wirelessly communicating information concerning the power tooland/or the battery pack to an external device.

31. The adapter according to embodiment 30, wherein the means forwirelessly communicating information comprises one or more of:

a wireless communication device, such as a wireless local area network(WLAN) device, e.g., WiFi (i.e. operating according to the wirelesscommunication protocol enumerated by IEEE 802.11),

a Bluetooth device,

a radio frequency (RF) communication device, or

a cellular or mobile telephone device.

32. The adapter according to embodiment 30 or 31, wherein thecommunicated information is one or any arbitrary combination of:

the measured remaining battery capacity and/or the estimated number ofadditional power tool operations of the same type that can be performedwith the remaining battery capacity according to any one of embodiments7-12,

the value(s) for one or more operating parameters, e.g., a maximumcurrent limit,stored in a memory of the battery pack and/or the power tool accordingto embodiment 13,the maintenance information according to embodiment 15 or 16,the detected discharge current and/or power tool recommendationaccording to embodiments 18-20,the anti-theft function or key according to embodiments 22 or 23,the person responsible for administering or managing the adapter,battery pack and/or power tool according to embodiment 24,the information to change the charging speed of the battery packaccording to embodiment 25 or 26the value(s) indicative of the operational state of the battery packand/or the power tool according to embodiment 27 or 28.

33. The adapter according to embodiment 30, 31 or 32, wherein thecommunicated information is a new value representative of a maximumcharged level of the battery pack.

The adapter according to embodiment 33, wherein the maximum chargedlevel determines a stopping point for a charging operation of thebattery pack.

35. The adapter according to any one of embodiments 25-34, wherein theexternal device is a smart phone.

36. The adapter according to any one of embodiments 25-34, wherein theexternal device comprises a portable computing device, such as a PDA,tablet computer or laptop computer.

37. The adapter according to any one of embodiments 25-34, wherein theexternal device comprises a desktop computer, server or a mainframecomputer.

38. The adapter according to any preceding embodiment, furthercomprising an input device configured or adapted to directly inputinstructions, data, information, operating parameters and/or userpreferences into the adapter.

39. The adapter according to embodiment 38, wherein the input devicecomprises a touch pad, touch screen, up/down button(s), push button(s)and/or toggle switch.

40. The adapter according to any preceding embodiment, furthercomprising a display.

41. The adapter according to embodiment 40, wherein the displaycomprises a liquid crystal display (LCD), a light-emitting diode (LED)display, such as an organic light-emitting diode (OLED) display, or anorganic electroluminescent (EL) display.

42. The adapter according to embodiment 40 or 41, wherein the display istouch pad or touch panel.

43. The adapter according to embodiment 40, 41 or 42, wherein thedisplay is configured to visually indicate any of the information,values or functions described in the preceding or following embodiments,such as the charge level (remaining battery capacity) of the batterypack, an alarm indicating overheating, the predicted number ofadditional power tool operations of the same type that may be performedbased upon the remaining battery capacity of the battery pack, the nameof the administrator of the power tool and the battery pack, maintenanceinformation, a charging speed value, a detected discharge current value,an operating parameter or any value indicative of the operational stateof the battery pack and/or the power tool.

44. The adapter according to any one of embodiments 40-43, wherein thedisplay is configured to visually indicate a maximum charged level ofthe battery pack.

45. The adapter according to any preceding embodiment, furthercomprising means for obtaining power from a charger, the adapter beingconfigured to supply a current to the battery pack in order to rechargeone or more battery cells located in the battery pack.

46. The adapter according to embodiment 45, wherein the means forobtaining power from a charger comprises at least one charging terminalreceiver configured to connect to at least one charging terminal of thecharger and to conduct current from the charger to the adapter.

47. The adapter according to embodiment 45, wherein the means forobtaining power from a charger comprises at least one wireless powerreceiving antenna, such as an induction coil, configured to generate acurrent when brought into proximity with at least one wireless powertransmitting antenna, such as an induction coil, of the charger.

48. The adapter according to embodiment 45, 46 or 47, further comprisinga belt hook configured to hang on a tool belt worn by a user, whereinthe means for obtaining power from the charger is disposed in or on thebelt hook.

49. The adapter according to any one of embodiments 45-48, furthercomprising a proximity sensor configured to output a signal, e.g., acharging initiation signal, when the charger is proximal to the adapter,such as a mechanical contact, a pressure sensor or switch, a radiofrequency identification (RFID) device, a magnet or magnetic fieldsensor, such as a reed switch or a Hall sensor, and/or an electricalresistance or capacitive sensor.

50. A portable battery pack charging system comprising:

the adapter according to any one of embodiments 45-49, and

a charger.

51. The portable battery pack charging system according to embodiment50, wherein the charger comprises at least one charging terminalconfigured to electrically connect to at least one charging terminalreceiver of the adapter.

52. The portable battery pack charging system according to embodiment50, wherein the charger comprises a wireless power transmitting antenna,such as an induction coil, configured to wirelessly transmit power to awireless power receiving antenna, such as an induction coil, of theadapter.

53. The portable battery pack charging system according to any one ofembodiments 50-52, wherein the charger comprises or is attached to aself-contained power supply.

54. The portable battery pack charging system according to embodiment53, wherein the self-contained power supply comprises a plurality ofrechargeable battery cells.

55. The portable battery pack charging system according to embodiment54, wherein the rechargeable battery cells of the charger have a highercharge storage capacity than battery cells of the battery pack andoutput a lower nominal current than the battery cells of the batterypack.

56. The portable battery pack charging system according to any one ofembodiments 50-55, further comprising means for attaching the charger toa user.

57. The portable battery pack charging system according to embodiment56, wherein the attaching means comprises a harness configured todetachably attach the charger to a limb or to the torso or back of theuser, such as a strap having a detachable hook and loop fastener, e.g.,Velcro (R), a strap having a detachable clasp or fastener, a belt or abackpack.

58. The portable battery pack charging system according to embodiment 56or 57, wherein the attaching means further comprises one of:

(i) a belt hook receiver comprising the at least one charging terminalconfigured to connect with the at least one charging terminal receiverof the adapter or

(ii) the wireless power transmitting antenna configured to wirelesslytransmit power to the wireless power receiving antenna of the adapter.

59. The portable battery pack charging system according to embodiment58, wherein the belt hook receiver or the wireless power transmittingantenna is configured to be attached to a tool belt worn by the user oris integral with the tool belt.

60. The portable battery pack charging system according to any one ofembodiments 50-59, further comprising charge control circuitryconfigured to determine the charging current supplied to the batterypack.

61. The portable battery pack charging system according to embodiment60, wherein the charge control circuitry is located in the adapterand/or in the battery pack.

62. The portable battery pack charging system according to embodiment60, wherein the charge control circuitry is located in the charger.

63. The portable battery pack charging system according to any one ofembodiments 50-62, wherein the charger stores sufficient energy to fullyrecharge the battery pack at least one time, more preferably at leastfive times and even more preferably at least ten times.

64. The portable battery pack charging system according to any one ofembodiments 50-63, wherein the charger further comprises a proximitysensor configured to output a signal, e.g., a charging initiationsignal, when the charger, or at least a charging terminal or wirelesspower transmitting antenna thereof, is proximal to the adapter, such asa mechanical contact, a pressure sensor or switch, a radio frequencyidentification (RFID) device, a magnet or magnetic field sensor, such asa reed switch or a Hall sensor, an electrical resistance or capacitivesensor.

65. The portable battery pack charging system according to embodiment64, wherein the proximity sensor is disposed in or on a belt hookreceiver of the charger.

66. The portable battery pack charging system according to embodiment 64or 65, wherein the proximity sensor comprises a magnetic field sensorcoupled to a controller of the charger and wherein the adapter comprisesa magnet.

67. The portable battery pack charging system according to embodiment 64or 65, wherein the proximity sensor comprises a RFID interrogatorcoupled to a controller of the charger and wherein the adapter comprisesa RFID tag.

70. A portable system for recharging a battery pack of a power tool,e.g., a hand-held power tool, comprising:

a charger configured or adapted to supply power for recharging at leastone battery cell in the battery pack, and

means for attaching the charger to a user.

71. The portable system according to embodiment 70, wherein the chargercomprises or is attached to a self-contained power supply.

72. The portable system according to embodiment 71, wherein theself-contained power supply comprises a plurality of rechargeablebattery cells.

73. The portable system according to embodiment 72, wherein therechargeable battery cells of the charger have a higher charge storagecapacity than battery cells of the battery pack and output a lowernominal current than the battery cells of the battery pack.

74. The portable system according to any one of embodiments 70-73,wherein the attaching means comprises a harness configured to detachablyattach the charger to a limb or to the torso or back of the user, suchas a strap having a detachable hook and loop fastener, e.g., Velcro (R),a strap having a detachable clasp or fastener, a belt or a backpack.

75. The portable system according to any one of embodiments 70-74,wherein the attaching means further comprises one of:

(i) a belt hook receiver comprising the at least one charging terminalconfigured to communicate charging current via a wired connection or

(ii) a wireless power transmitting antenna configured to wirelesslytransmit power for use in generating a charging current.

76. The portable system according to embodiment 75, wherein the wirelesspower transmitting antenna comprises an induction coil.

77. The portable system according to embodiment 75 or 76, wherein thebelt hook receiver or the wireless power transmitting antenna isconfigured to be attached to a tool belt worn by the user or is integralwith the tool belt.

78. The portable system according to any one of embodiments 75-77,wherein the belt hook receiver is configured or adapted to engage a belthook attached to the battery pack.

79. The portable system according to embodiment 78, wherein the belthook receiver further comprises a proximity sensor configured to outputa signal, e.g., a charging initiation signal, when the charging terminalor the wireless power transmitting antenna is proximal to the belt hookattached to the battery pack, the proximity sensor including, but notbeing limited to, a mechanical contact, a pressure sensor or switch, aradio frequency identification (RFID) device, a magnet or magnetic fieldsensor, such as a reed switch or a Hall sensor, and/or an electricalresistance or capacitive sensor.

80. The portable system according to any one of embodiments 70-79,further comprising: a battery pack connected to a belt hook thatincludes one of a charging terminal receiver or a wireless powerreceiving antenna.

81. The portable system according to embodiment 80, wherein the wirelesspower receiving antenna comprises an induction coil.

82. The portable system according to embodiment 80 or 81, wherein thebelt hook is attached to an adapter that is electrically connected to atleast one battery cell of the battery pack.

83. The portable system according to embodiment 82, wherein the adaptercomprises wires configured or adapted to conduct a charging current fromthe charger to the battery pack.

84. The portable system according to embodiment 83, wherein the adapterfurther comprises a controller and a memory configured or adapted tocontrol the battery charging operation.

85. The portable system according to any one of embodiments 70-84,further comprising charge control circuitry configured to determine thecharging current supplied to the battery pack.

86. The portable system according to embodiment 85, wherein the chargecontrol circuitry is located in the charger.

87. The portable system according to embodiment 85, wherein the chargecontrol circuitry is located in the battery pack or in the adapterelectronically connected to the battery pack.

88. The portable system according to any one of embodiments 80-87,wherein the charger stores sufficient energy to fully recharge thebattery pack at least one time, more preferably at least five times andeven more preferably at least ten times.

90. A method for recharging a battery pack comprising:

attaching a portable charger to a user, the portable charger comprisingor being attached to a self-contained power supply and a first chargingport of the portable charger is disposed on a belt worn by the user,

hanging the battery pack on the belt while the battery pack isphysically engaged and in electrical communication with a power tool,and

initiating a transfer of power from the charger to the battery pack whenthe first charging port is proximal to a second charging port that is inelectrical communication with at least one battery cell of the batterypack.

91. The method according to embodiment 90, wherein the first and secondcharging ports comprise complementary terminals configured or adapted toconduct a current from the charger to the at least one battery cell ofthe battery pack, more preferably a charging current.

92. The method according to embodiment 90, wherein the first chargingport comprises a wireless power transmitting antenna and the secondcharging port comprises a wireless power receiving antenna.

93. The method according to embodiment 92, wherein the wireless powertransmitting antenna and the wireless power receiving antenna eachcomprise an induction coil.

94. The method according to embodiment 92 or 93, wherein the transfer ofpower is performed by induction coupling, more preferably resonantinduction coupling.

95. The method according to any one of embodiments 90-94, furthercomprising detecting the proximity of the first charging port to thesecond charging port and initiating the transfer of power upon detectionof the proximity.

96. The method according to embodiment 95, further comprisingterminating the transfer of power upon detecting that the first chargingport is no longer proximal to the second charging port.

97. The method according to embodiment 95 or 96, wherein proximity isdetected based upon a magnetic field, pressure, a radio signal, anelectrical resistance or capacitance, or a mechanical movement.

98. The method according to any one of embodiments 90-97, wherein thesecond charging port is disposed on or in a belt hook attached to thebattery pack.

99. The method according to embodiment 98, wherein the belt hook isattached to an adapter that is physically engaged with the battery packor the power tool.

100. The method according to embodiment 98, wherein the adapter controlsthe charging operation.

101. The method according to embodiment 98, wherein the belt hook isdirectly attached to the battery pack.

102. The method according to embodiment 101, wherein the chargercontrols the charging operation.

103. The method according to embodiment 101, wherein a controller of thebattery pack controls the charging operation.

105. A method for recharging a battery pack comprising:

transferring power from the charger to a battery pack attached to apower tool when a first charging port of the charger is proximal to asecond charging port electrical communicating with at least one batterycell of the battery pack.

106. The method according to embodiment 105, wherein the first andsecond charging ports are disposed on or adjacent a belt worn by theuser.

107. The method according to embodiment 105 or 106, wherein the chargeris attached to the user while the user performs power tool operationsand comprises or is attached to a self-contained DC power supply.

110. An adapter for a power tool powered by a detachable battery pack,comprising:

at least one communication port configured to electrically communicatewith a controller, such as at least one microprocessor, located in thepower tool and/or in the battery pack, and

means for wirelessly communicating information concerning the power tooland/or the battery pack to an external device.

111. The adapter according to embodiment 110, wherein the means forwirelessly communicating information comprises one or more of:

a wireless communication device, such as a wireless local area network(WLAN) device, e.g., WiFi (i.e. operating according to the wirelesscommunication protocol enumerated by IEEE 802.11),

a Bluetooth device,

a radio frequency (RF) communication device, or

a cellular or mobile telephone device.

112. The adapter according to embodiment 100 or 101, wherein thecommunicated information is one or any arbitrary combination of:

the measured remaining battery capacity and/or the estimated number ofadditional power tool operations of the same type that can be performedwith the remaining battery capacity according to any one of embodiments7-12,

the value(s) for one or more operating parameters, e.g., a maximumcurrent limit, stored in a memory of the battery pack and/or the powertool according to embodiment 13,

the maintenance information according to embodiment 15 or 16,the detected discharge current and/or power tool recommendationaccording to embodiments 18-20,the anti-theft function or key according to embodiments 22 or 23,the person responsible for administering or managing the adapter,battery pack and/or power tool according to embodiment 24,the information to change the charging speed of the battery packaccording to embodiment 25 or 26the value(s) indicative of the operational state of the battery packand/or the power tool according to embodiment 27 or 28.

113. The adapter according to any one of embodiments 110-112, whereinthe external device is a smart phone.

114. The adapter according to any one of embodiments 110-112, whereinthe external device comprises a portable computing device, such as aPDA, tablet computer or laptop computer.

115. The adapter according to any one of embodiments 110-112, whereinthe external device comprises a desktop computer, server or a mainframecomputer.

116. The adapter according to any one of embodiments 110-115, furthercomprising an input device, such as a touch pad, touch screen, pushbutton(s) and/or toggle switch, the input device being configured oradapted to enable a user to input instructions directly into theadapter.

117. The adapter according to any one of embodiments 110-116, furthercomprising a display.

118. The adapter according to embodiment 117, wherein the displaycomprises a liquid crystal display (LCD), a light-emitting diode (LED)display, such as an organic light-emitting diode (OLED) display, or anorganic electroluminescent (EL) display.

119. The adapter according to embodiment 117 or 118, wherein the displayis touch pad or touch panel.

120. The adapter according to any one of embodiments 117-119, whereinthe display is configured to visually indicate any of the information,values or functions described in the preceding or following embodiments,such as the charge level (remaining battery capacity) of the batterypack, an alarm indicating overheating, the predicted number ofadditional power tool operations that may be performed based upon theremaining battery capacity of the battery pack, the name of theadministrator of the power tool and the battery pack, maintenanceinformation, a charging speed value, a maximum charged value of thebattery pack, a detected discharge current value, an operating parameteror any value(s) indicative of the operational state of the battery packand/or the power tool.

121. The adapter according to any one of embodiments 110-120, furthercomprising means for obtaining power from a charger, the adapter beingconfigured to supply a current to the battery pack in order to rechargeone or more battery cells located in the battery pack.

122. The adapter according to embodiment 121, wherein the means forobtaining power from a charger comprises at least one charging terminalreceiver configured to connect to at least one charging terminal of thecharger and to conduct current from the charger to the adapter.

123. The adapter according to embodiment 121, wherein the means forobtaining power from a charger comprises at least one wireless powerreceiving antenna, such as an induction coil, configured to generate acurrent when brought into proximity with at least one wireless powertransmitting antenna, such as an induction coil, of the charger.

124. The adapter according to any one of embodiments 121-123, furthercomprising a belt hook configured to hang on a tool belt worn by a user,wherein the means for obtaining power from the charger is disposed in oron the belt hook.

125. The adapter according to any one of embodiments 121-124, furthercomprising a proximity sensor configured to output a signal, e.g., acharging initiation signal, when the charger is proximal to the adapter,such as a mechanical contact, a pressure sensor or switch, a radiofrequency identification (RFID) device, a magnet or magnetic fieldsensor, such as a reed switch or a Hall sensor, an electrical resistanceor capacitive sensor.

126. The adapter according to any one of embodiments 110-125, whereinthe adapter is configured to be at least partially disposed in a spacebetween a power tool housing and the battery pack when the power toolhousing and battery pack are attached to each other.

127. The adapter according to any one of embodiments 110-126, whereinthe adapter is configured to be attachable to and detachable from thepower tool housing only when the battery pack is detached from thehousing.

128. The adapter according to any one of embodiments 110-127, wherein:

the adapter is configured to be attached to and detached from the powertool housing in a first direction, preferably a longitudinal directionrelative to a handle of the power tool,

the battery pack is configured to be attached to and detached from thepower tool housing in a second direction, preferably a lateral directionrelative to the handle of the power tool, and

the first direction is substantially perpendicular to the seconddirection.

129. The adapter according to any one of embodiments 110-128, whereinthe adapter is affixable to the housing via a threaded fastener, e.g. ascrew or a bolt and wherein the adapter optionally comprises acylindrical portion, through which the threaded fastener is insertablein order to tighten the adapter onto the power tool housing.

130. A method comprising:

wirelessly communicating information between an external device and oneof a power tool and a battery pack.

131. The method according to embodiment 130, wherein the information iscommunicated via an adapter physically and electronically connected tothe power tool and/or to the battery pack.

132. The method according to embodiment 131, wherein the adapterreceives a wireless signal from the external device and communicates anelectronic signal to the power tool and/or to the battery pack.

133. The method according to any one of embodiments 130-132, wherein theexternal device is a smart phone.

134. The method according to any one of embodiments 130-132, wherein theexternal device comprises a portable computing device, such as a PDA,tablet computer or laptop computer.

135. The method according to any one of embodiments 130-132, wherein theexternal device comprises a desktop computer, server or a mainframecomputer.

136. The method according to any one of embodiments 130-135, wherein thecommunicated information comprises a measured remaining battery capacityand/or an estimated number of additional power tool operations of thesame type that can be performed with the remaining battery capacity.

137. The method according to any one of embodiments 130-136, wherein thecommunicated information comprises one or more values corresponding toone or more operating parameters, e.g., a maximum current limit, storedin a memory of the battery pack and/or the power tool.

138. The method according to any one of embodiments 130-137, wherein thecommunicated information comprises maintenance information for the powertool and/or the battery pack.

139. The method according to embodiment 138, wherein the maintenanceinformation includes the date and/or the result of the last maintenancecheck/inspection.

140. The method according to embodiment 138 or 139, wherein themaintenance information includes:

the accumulated or total usage (operation) time of the power tool and/orthe battery pack (40),

the available charge or charge status (e.g., remaining battery capacity)of the battery pack

the number of charging cycles experienced by the battery pack, and/orthe condition of one or more battery cells in the battery pack, e.g., ascalculated from an internal impedance measurement of the batterycell(s).

141. The method according to any one of embodiments 138-140, wherein themaintenance information includes:

the expected remaining service life of one or more replaceable parts inthe power tool and/or the battery pack,

a maintenance schedule for the power tool and/or the adapter and/or thebattery pack,

a usage history of the power tool and/or the adapter and/or the batterypack,

the name of a person responsible for administering or managing theadapter, battery pack and/or power tool, and/or

a serial number of the battery pack and/or the power tool.

142. The method according to any one of embodiments 138-141, wherein themaintenance information includes:

the voltage of one or more (e.g., either individually or a summation oftwo or more) battery cell(s),

the discharge current of one or more (e.g., either individually or asummation of two or more) battery cell(s), and/or

the temperature of one or more (e.g., either individually or a summationof two or more) battery cell(s).

143. The method according to any one of embodiments 138-142, wherein themaintenance information includes the number of times that the batterypack and/or the power tool has been switched ON and/or switched OFF.

144. The method according to any one of embodiments 138-143, wherein themaintenance information includes the amount of charging or dischargingthat has occurred within a predetermined time period, e.g., the amountof discharged power during the previous 2 hours.

145. The method according to any one of embodiments 130-144, wherein thecommunicated information comprises a detected discharge current and/or apower tool recommendation generated based upon the detected dischargecurrent.

146. The method according to any one of embodiments 130-145, wherein thecommunicated information comprises an anti-theft function or key.

147. The method according to any one of embodiments 130-146, wherein thecommunicated information comprises a person responsible foradministering or managing the adapter, battery pack and/or power tool.

148. The method according to any one of embodiments 130-147, wherein thecommunicated information comprises an instruction to change a chargingspeed of the battery pack, e.g., by increasing a charging current and/ora battery pack temperature threshold.

149. The method according to any one of embodiments 130-148, wherein thecommunicated information comprises one or more values indicative of theoperational state of the battery pack and/or the power tool.

150. The method according to any one of embodiments 130-149, wherein thecommunicated information comprises one or more values indicative of amaximum charged level of the battery pack.

151. A power tool system comprising:

a hand-held power tool comprising a housing having a battery packinterface, an electrically-driven device and a first connector,

a battery pack is adapted or configured to be detachably attached, e.g.,directly, to the battery pack interface and to supply current to theelectrically-driven device, and

an adapter comprising a second connector configured to be physically andelectrically connected with the first connector in a detachable manner,the adapter being configured to:

receive power from the battery pack via the hand-held power tool and

provide at least one additional electrical function to the hand-heldpower tool or to perform at least one additional electrical functionthat the hand-held power tool is not otherwise capable of performing,

wherein the adapter is at least partially disposed in a space betweenthe housing and the battery pack when the housing and battery pack areattached to each other.

152. The power tool system as in embodiment 151, wherein the batterypack is configured to be attached to and detached from the housingregardless of whether the adapter is attached to or detached from thehousing.

153. The power tool system as in embodiment 151 or 152, wherein theadapter is configured to be attachable to and detachable from thehousing only when the battery pack is detached from the housing.

154. The power tool system as in any one of embodiments 151-153,wherein:

the adapter is configured to be slidably attached to and detached fromthe housing in a first direction, preferably a longitudinal directionrelative to a handle of the power tool,

the battery pack is configured to be slidably attached to and detachedfrom the housing in a second direction, preferably a lateral directionrelative to the handle of the power tool, and

the first direction is substantially perpendicular to the seconddirection.

155. The power tool system as in any one of embodiments 151-154, whereinthe housing and the battery pack together define an opening therebetweenthat visibly exposes at least a portion of the adapter while the adapteris attached to the housing (e.g., the opening is defined through anouter surface of the hand-held power tool and/or the battery pack).

156. The power tool system as in embodiment 155, wherein the adapter isconfigured to fit in the opening with no significant clearance (e.g.with the minimum amount of clearance necessary for manufacturingtolerance purposes) when the adapter and the battery pack are attachedto the housing.

157. The power tool system as in embodiment 155 or 156, furthercomprising:

a dummy adapter configured to be detachably attached to the housinginstead of the adapter, the dummy adapter fitting in the opening with nosubstantial clearance when the dummy adapter and the battery pack areattached to the housing.

158. The power tool system as in embodiment 157, wherein the dummyadapter is configured to cover the first connector when the dummyadapter is attached to the housing.

159. The power tool system as in any one of embodiments 151-158,wherein:

the first connecter is a female connector that comprises at least onecontact pin and a peripheral wall that surrounds the at least onecontact pin, and

the second connector is a male connector that comprises at least onehole configured to receive the at least one contact pin and at least onecontact plate (contact terminal) located within the at least one holeconfigured to physically and electrically contact the at least onecontact pin.

160. The power tool system as in any one of embodiments 151-159, whereinthe adapter is affixable to the housing via a threaded fastener, e.g. ascrew or a bolt.

161. The power tool system as in embodiment 160, wherein the adapter isprimarily positioned with respect to the housing by the coupling of thefirst and second connectors and is secondarily positioned with respectto the housing by the tightened threaded fastener.

162. The power tool system as in embodiment 160 or 161, wherein theadapter comprises a cylindrical portion, through which the threadedfastener is insertable in order to tighten the adapter onto the powertool housing.

163. The power tool system as in embodiment 162, wherein the cylindricalportion is exposed through an outer surface of the power tool and isconfigured to be attached to a strap.

164. The power tool system as in any one of embodiments 151-163, wherein

the power tool system comprises a plurality of adapters, and

each adapter is configured to attach to the housing and to provide atleast one different electrical function to the hand-held power tool orto perform at least one different electrical function.

165. The power tool system according to any one of embodiments 151-164,wherein the adapter is configured or adapted to:

wirelessly communicate information to and/or from the power tool, suchas any of the information identified above or below, includingwirelessly communicating with an external device, such as a basestation, a workstation, a computer, a personal data assistant, a smartphone, etc.

166. The power tool system according to any one of embodiments 151-165,wherein the adapter is configured or adapted to:

display information concerning the power tool on a display, such as anyof the information identified above or below.

167. The power tool system according to any one of embodiments 151-166,wherein the adapter is configured or adapted to:

measure and/or display and/or communicate remaining battery capacity ofthe battery pack and/or the estimated number of additional power tooloperations of the same type that can be performed with the remainingbattery capacity.

168. The power tool system according to any one of embodiments 151-167,wherein the adapter is configured or adapted to:

measure and/or display and/or communicate the value(s) for one or moreoperating parameters, e.g., a maximum current limit, stored in a memoryof the battery pack and/or the power tool.

169. The power tool system according to any one of embodiments 151-168,wherein the adapter is configured or adapted to:

measure and/or display and/or communicate maintenance information, suchas one or more of (i) a date of a last maintenance check/inspection,(ii) the result of the last maintenance check/inspection, (iii) theaccumulated or total usage (operation) time of the power tool and/or thebattery pack, (iv) the available charge or charge status (remainingbattery capacity) of the battery pack, (v) the number of charging cyclesexperienced by the battery pack, (vi) the condition of one or morebattery cells in the battery pack, e.g., as calculated from an internalimpedance measurement of the battery cell(s), (vii) the expectedremaining service life of one or more replaceable parts in the powertool and/or the battery pack and/or (viii) a maintenance schedule forthe power tool and/or the battery pack.

170. The power tool system according to any one of embodiments 151-169,wherein the adapter is configured or adapted to:

measure and/or display and/or communicate a detected discharge currentand/or power tool recommendation.

171. The power tool system according to any one of embodiments 151-170,wherein the adapter is configured or adapted to:

provide an anti-theft function or key.

172. The power tool system according to any one of embodiments 151-171,wherein the adapter is configured or adapted to:

identify or communicate the person responsible for administering ormanaging the adapter, battery pack and/or power tool.

173. The power tool system according to any one of embodiments 151-172,wherein the adapter is configured or adapted to:

input and/or display and/or communicate information concerning a changeof the charging speed of the battery pack.

174. The power tool system according to any one of embodiments 151-173,wherein the adapter is configured or adapted to:

measure and/or display and/or communicate value(s) indicative of theoperational state of the battery pack and/or the power tool.

175. The power tool system according to any one of embodiments 151-174,further comprising a light coupled to a body of the adapter via aflexible arm.

176. The power tool system according to any one of embodiments 151-164,wherein the adapter is configured or adapted to:

wirelessly communicate information to and/or from the power tool, suchas any of the information identified above or below, includingwirelessly communicating with an external device, such as a basestation, a workstation, a computer, a personal data assistant, a smartphone, etc.,

display information concerning the power tool on a display, such as anyof the information identified above or below,

measure and/or display and/or communicate remaining battery capacity ofthe battery pack and/or the estimated number of additional power tooloperations of the same type that can be performed with the remainingbattery capacity,

measure and/or display and/or communicate the value(s) for one or moreoperating parameters, e.g., a maximum current limit, stored in a memoryof the battery pack and/or the power tool,

measure and/or display and/or communicate maintenance information, suchas one or more of (i) a date of a last maintenance check/inspection,(ii) the result of the last maintenance check/inspection, (iii) theaccumulated or total usage (operation) time of the power tool and/or thebattery pack, (iv) the available charge or charge status (remainingbattery capacity) of the battery pack, (v) the number of charging cyclesexperienced by the battery pack, (vi) the condition of one or morebattery cells in the battery pack, e.g., as calculated from an internalimpedance measurement of the battery cell(s), (vii) the expectedremaining service life of one or more replaceable parts in the powertool and/or the battery pack and/or (viii) a maintenance schedule forthe power tool and/or the battery pack,

measure and/or display and/or communicate a detected discharge currentand/or power tool recommendation,provide an anti-theft function or key,identify or communicate the person responsible for administering ormanaging the adapter, battery pack and/or power tool,input and/or display and/or communicate information concerning a changeof the charging speed of the battery pack, and/ormeasure and/or display and/or communicate value(s) indicative of theoperational state of the battery pack and/or the power tool, and/orperform or execute any other function described in the specificationabove.

177. The power tool system any one of embodiments 151-176, wherein:

the power tool system comprises a plurality of hand-held power tools,and

each adapter is configured to attach to the housing of any one of thehand-held power tools and provide a different function to the hand-heldpower tool.

178. An adapter according to any one of embodiments 151-177 without thepower tool and battery pack.

181. An adapter for a hand-held power tool powered by a battery pack,the adapter comprising:

a connector configured to be physically and electrically connected in adetachable manner with a corresponding connector disposed on thehand-held power tool,

means for receiving power from the battery pack via the hand-held powertool and the connector,

means for performing at least one additional electrical function thatthe hand-held power tool is not otherwise capable of performing,

wherein the adapter is configured to be at least partially disposed in aspace between a housing of the hand-held power tool and the battery packwhen the housing and battery pack are attached to each other.

182. The adapter as in embodiment 181, wherein the adapter is configuredto be attachable to and detachable from the housing only when thebattery pack is detached from the housing.

183. The adapter as in embodiment 181 or 182, wherein:

the adapter is configured to be slidably attached to and detached fromthe housing in a first direction, preferably a longitudinal directionrelative to a handle of the power tool,

the battery pack is configured to be slidably attached to and detachedfrom the housing in a second direction, preferably a lateral directionrelative to the handle of the power tool, and

the first direction is substantially perpendicular to the seconddirection.

184. The adapter as in any one of embodiments 181-183, wherein at leasta portion of the adapter is configured to be visibly exposed through anopening defined by the housing and the battery pack while the adapter isattached to the housing (e.g., the opening is defined through an outersurface of the hand-held power tool and/or the battery pack).

185. The adapter as in embodiment 184, wherein the adapter is configuredto fit in the opening with no significant clearance (e.g. with theminimum amount of clearance necessary for manufacturing tolerancepurposes) when the adapter and the battery pack are attached to thehousing.

186. The adapter as in any one of embodiments 181-185, wherein:

the connecter is a female connector that comprises at least one contactpin and a peripheral wall that surrounds the at least one contact pin,and

the corresponding connector is a male connector that comprises at leastone hole configured to receive the at least one contact pin and at leastone contact plate (contact terminal) located within the at least onehole configured to physically and electrically contact the at least onecontact pin.

187. The adapter as in any one of embodiments 181-186, wherein theadapter is configured to be affixable to the housing via a threadedfastener, e.g. a screw or a bolt.

188. The adapter as in embodiment 187, wherein the adapter is configuredto be primarily positioned with respect to the housing by the couplingof the connectors and is secondarily positioned with respect to thehousing by the tightened threaded fastener.

189. The adapter as in embodiment 187 or 188, wherein the adaptercomprises a cylindrical portion, through which the threaded fastener isinsertable in order to tighten the adapter onto the power tool housing.

190. The adapter as in claim 189, wherein the cylindrical portion isconfigured to be exposed through an outer surface of the power tool andis configured to be attached to a strap.

191. The adapter as in any one of claims 181-190, further comprising thefeatures of any one of the adapters according to claim 1, 2 or 7-49.

192. The adapter as in any one of claims 181-191, further comprising alight coupled to a body of the adapter via a flexible arm.

REFERENCE SIGNS LIST

-   -   1, 1′, 1″, 1′″, 1″, 1′″″: power tool system    -   10, 10′: cordless power tool    -   11: electronic unit    -   12: controller    -   13: circuit board    -   14: discharge detector    -   16: memory    -   18: communicator    -   20: power FET    -   22: battery terminals    -   24: adapter communication terminal(s)    -   25: adapter power terminal(s)    -   26: battery pack communication terminal(s) (I/O terminal(s))    -   28: trigger switch    -   30: tool chuck    -   32: housing    -   33: slots    -   34: battery pack interface    -   35: space between power tool housing and battery pack    -   36: opening    -   37: female connector    -   38: contact pins    -   39: peripheral wall    -   40, 40′: battery pack    -   42: controller    -   44: charge/discharge detector    -   46: memory    -   48: communicator    -   50: battery cell(s)    -   52: battery terminals    -   54: adapter communication terminal(s)    -   55: adapter power terminal(s)    -   56: power tool communication terminal(s) (I/O terminal(s))    -   58: switch    -   60: charging terminals    -   70, 70′, 70″, 70′″, 70″″, 70′″″: adapter    -   72: controller    -   73: circuit board    -   74: communication terminal(s)    -   75: power terminal(s)    -   76: memory    -   78: communicator    -   79: antenna    -   80: display    -   81: LCD driver    -   82: battery terminals    -   84: charging terminals    -   85: charging terminal receivers    -   86: charger communication terminal(s) (I/O terminal(s))    -   88: switch    -   90: diode    -   91: cylindrical portion    -   92: threaded fastener    -   93: ribs    -   94: male connector    -   96: holes    -   97: contact terminals    -   98: projecting bodies    -   100: external device    -   102: controller    -   104: display    -   106: memory    -   108: communicator    -   120: charger    -   122: controller    -   124: adapter communication terminal(s)    -   126: memory    -   128: communicator    -   130: power source    -   132: charging terminals    -   138: switch    -   140: DC power supply    -   142: flexible power cord    -   144: belt    -   146: belt hook receiver    -   148: belt hook    -   150: strap    -   152: light    -   153: LED    -   154: flexible arm    -   155: contact current generator    -   156: ON/OFF switch    -   158: FET    -   170: dummy adapter    -   M: electric motor of power tool

1. A portable system for recharging a battery pack while the batterypack is attached and electrically connected to a hand-held power tool,comprising: a charger configured to supply power for recharging batterycells in the battery pack, wherein the charger comprises or is attachedto a self-contained power supply, and means for attaching the charger toa user, wherein the attaching means comprises a belt configured to beworn around the user's waist and a belt hook receiver supporting atleast one charging terminal of the charger configured to communicatecharging current via a wired connection.
 2. (canceled)
 3. The portablesystem according to claim 1, wherein the self-contained power supplycomprises a plurality of rechargeable battery cells.
 4. The portablesystem according to claim 3, wherein the rechargeable battery cells ofthe charger have a higher charge storage capacity than the battery cellsof the battery pack and output a lower nominal current than the batterycells of the battery pack. 5-10. (canceled)
 11. The portable systemaccording to claim 4, wherein the belt hook receiver is configured toengage a belt hook attached to the power tool or a belt hook attached tothe battery pack.
 12. (canceled)
 13. The portable system according toclaim 11, wherein the belt hook receiver further comprises a proximitysensor configured to output a charging initiation signal when thecharging terminal is proximal to the belt hook, wherein the proximitysensor includes one or more of a mechanical contact, a pressure sensoror switch, a radio frequency identification (RFID) device, a magnet ormagnetic field sensor, such as a reed switch or a Hall sensor, and/or anelectrical resistance or capacitive sensor.
 14. The portable systemaccording to 13, further comprising: a second battery pack connected toa belt hook that includes a charging terminal receiver. 15-21.(canceled)
 22. A method for recharging a battery pack comprising:attaching a portable charger to a user, wherein the portable chargercomprises or is attached to a self-contained power supply and wherein afirst charging port of the portable charger is disposed on a belt wornby the user, hanging the battery pack on the belt while the battery packis physically engaged and in electrical communication with a power tool,and initiating a transfer of power from the charger to the battery packwhen the first charging port is at least proximal to a second chargingport that is in electrical communication with at least one battery cellof the battery pack.
 23. The method according to claim 22, wherein thefirst and second charging ports comprise complementary terminalsconfigured to conduct a charging current from the charger to the atleast one battery cell of the battery pack. 24-26. (canceled)
 27. Themethod according to claim 23, further comprising detecting a proximityof the first charging port to the second charging port and initiatingthe transfer of power upon detection of the proximity.
 28. The methodaccording to claim 27, further comprising terminating the transfer ofpower upon detecting that the first charging port is no longer proximalto the second charging port.
 29. The method according to claim 27,wherein proximity is detected based upon a magnetic field, a pressure, aradio signal, an electrical resistance or capacitance, or a mechanicalmovement.
 30. The method according to claim 23, wherein the secondcharging port is disposed on or in a belt hook attached to the batterypack or to the power tool.
 31. The method according to claim 30, whereinthe belt hook is attached to an adapter that is physically engaged withthe battery pack or the power tool.
 32. The method according to claim31, wherein the adapter controls the charging operation.
 33. The methodaccording to claim 30, wherein the belt hook is directly attached to thebattery pack.
 34. The method according to claim 33, wherein the chargercontrols the charging operation.
 35. The method according to claim 33,wherein a controller of the battery pack controls the chargingoperation.
 36. A method for recharging a battery pack comprising:transferring power from a charger to the battery pack while the batterypack is attached to a power tool upon detecting the proximity a firstcharging port of the charger to a second charging port that is inelectrical communication with at least one battery cell of the batterypack.
 37. The method according to claim 36, wherein the first and secondcharging ports are disposed on or adjacent a belt worn by a user. 38.The method according to claim 36, wherein the charger is attached to theuser while the user performs power tool operations and comprises or isattached to a self-contained DC power supply. 39-62. (canceled)